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This Thesis is regarding the Flanging and Bending of Advanced High Strength Steels (AHSS)- a class of High Strength Steels being increasingly used by the automotive industry today. Four processes are under study here: wipe bending, shrink flanging, stretch flanging and hat-shape bending. Each of the above processes are used in many automotive parts, and each process has its own challenges- springback, wrinkling or thickening of material, material failure by thinning or edge-cracking.The Thesis describes the use of Finite Element Analysis (FEA) by means of commercially available software called PamStamp to simulate the above processes for a number of AHSS grades to predict part quality. Experiments were designed based on the FEA simulations. Experiments for hat-shape bending process were successfully conducted. A roadmap for conducting experiments for wipe bending, shrink flanging & stretch flanging is also described.Upon the completion of hat-shape bending experiments for four materials: DP590, DP980, CP800 & TRIP1180- the profiles of the formed parts were digitized into co-ordinates, and the corresponding springback angles were measured. The results were analyzed and interpreted, with the aid of post-experimental simulations. |
