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Springback prediction and reduction in deep drawing under influence of unloading modulus degradation

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Abstract

Springback is considered as one of the major problems in deep drawing of high-strength steels (HSS) and advanced high-strength steels (AHSS) which occurs during the unloading of part from the tools. With an ever increasing demand on the automotive manufactures for the production of lightweight automobile structures and increased crash performance, the use of HSS and AHSS is becoming extensive. For the accurate prediction of springback, unloading behavior of dual phase steels DP600, DP1000 and cold rolled steel DC04 for the deep drawing process is investigated and a strategy for the reduction of springback based on variable blankholder force is also presented. Cyclic tension compression tests and LS-Opt software are used for the identification of material parameters for Yoshida-Uemori (YU) model. Degradation of the Young’s modulus is found to be 28 and 26 and 14 % from the initial Young’s modulus for DP600, DP1000 and for the DC04 respectively for the saturated value. A finite element model is generated in LS-DYNA based on the kinematic hardening material model, namely Yoshida-Uemori (YU) model. The validation of numerical simulations is also carried out by the real deep drawing experiments. The springback could be predicted with the maximum deviation of 1.1 mm for these materials. For DP1000, the maximum springback is reduced by 24.5 %, for DP600 33.3 and 48.7 % for DC04 by the application of monotonic blankholder force instead of a constant blankholder force of 80 kN. It is concluded that despite the reduction of Young’s modulus, the springback can be reduced for these materials by increasing the blankholder force only in last 13 % of the punch travel.

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Acknowledgements

This work is done as part of the SFB 708, TP C3. The authors thank the Deutsche Forschungsgemeinschaft for their financial support. The authors also thank Prof. Karl Roll for his valuable suggestions.

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Authors and Affiliations

  1. Institute of Forming Technology and Lightweight Construction, TU Dortmund, 44227, Dortmund, Germany

    Hamad ul Hassan, Alper Güner, Nooman Ben Khalifa & A. Erman Tekkaya

  2. Department of Design and Manufacturing, Brandenburg University of Technology, 03046, Cottbus, Germany

    Fawad Maqbool

  3. Interdisciplinary Centre for Advanced Materials Simulation, Ruhr-University Bochum, 44801, Bochum, Germany

    Alexander Hartmaier

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  1. Hamad ul Hassan
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  2. Fawad Maqbool
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  3. Alper Güner
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  6. A. Erman Tekkaya
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Correspondence to Hamad ul Hassan.

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ul Hassan, H., Maqbool, F., Güner, A. et al. Springback prediction and reduction in deep drawing under influence of unloading modulus degradation. Int J Mater Form 9, 619–633 (2016). https://doi.org/10.1007/s12289-015-1248-5

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  • DOI: https://doi.org/10.1007/s12289-015-1248-5

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