12
Investigation on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany [email protected], [email protected] Abstract: There are several test procedures to rate the sensitivity of the formability of steels with punched edges but only one is fixed as a standard. The influence on the results of an ISO 16630 hole expansion are listed and some of the main influences evaluated with the help of an optical measurement system. Due to the high influence of a technician’s perception on the ISO 16630 test result some optimised procedures are presented and compared. The potential of the offline analysis of such an expansion test is demonstrated. Keywords: formability, high strength steel, material testing, hole expansion 1. PROBLEM DISCRIPTION The increasing demands for lightweight design in the automobile and truck sector have significantly pushed the innovations of new steel grades. In addition to the body in white, the chassis is today and will be in the future a wide application area for modern steel grades. Thus the steel producers have accepted the challenge to combine formability and strength. The thermomechanically rolled steels, dual phase or bainitic steels are promising regarding this demand. To use their good forming and performance characteristics the steel has to be described in detail with the relevant mechanical properties. For the estimation of the material failure under forming conditions the forming limit curve (FLC) [ISO 12004-2] is very common. In some cases the FLC has its deficits but there is an optimisation approach [Merklein et al., 2010]. In the production of chassis parts there are often operations which can not be estimated by the FLC. Zones of a part that get punched and afterwards formed into a collar or a Blankholder Specimen Punch Die a b Blankholder Specimen Punch Die Blankholder Specimen Punch Die Blankholder Specimen Punch Die a b Figure 1; a) Schematic description of the ISO 16630 tool b) example for a specimen during forming

Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany [email protected],

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Page 1: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

Investigation on punched edge formability

Matthias Schneider, Uwe Eggers

Salzgitter Mannesmann Forschung GmbH

Eisenhüttenstrasse 99, 38239 Germany

[email protected], [email protected]

Abstract: There are several test procedures to rate the sensitivity of the formability of

steels with punched edges but only one is fixed as a standard. The influence on the

results of an ISO 16630 hole expansion are listed and some of the main influences

evaluated with the help of an optical measurement system. Due to the high influence of

a technician’s perception on the ISO 16630 test result some optimised procedures are

presented and compared. The potential of the offline analysis of such an expansion test

is demonstrated.

Keywords: formability, high strength steel, material testing, hole expansion

1. PROBLEM DISCRIPTION

The increasing demands for lightweight design in the automobile and truck sector have

significantly pushed the innovations of new steel grades. In addition to the body in

white, the chassis is today and will be in the future a wide application area for modern

steel grades. Thus the steel producers have accepted the challenge to combine

formability and strength. The thermomechanically rolled steels, dual phase or bainitic

steels are promising regarding this demand. To use their good forming and performance

characteristics the steel has to be described in detail with the relevant mechanical

properties. For the estimation of the material failure under forming conditions the

forming limit curve (FLC) [ISO 12004-2] is very common. In some cases the FLC has

its deficits but there is an optimisation approach [Merklein et al., 2010].

In the production of chassis parts there are often operations which can not be estimated

by the FLC. Zones of a part that get punched and afterwards formed into a collar or a

Blankholder

Specimen

Punch

Die

a b

Blankholder

Specimen

Punch

Die

Blankholder

Specimen

Punch

Die

Blankholder

Specimen

Punch

Die

a b

Figure 1; a) Schematic description of the ISO 16630 tool

b) example for a specimen during forming

Page 2: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

flange. These punched edges in high strength steels are less formable than the untreated

material. Therefore there is a need for an additional test to determine a characteristic

value parallel to the FLC to estimate the edge behaviour. At the moment the ISO 16630

[ISO 16630] is the only test procedure that is fixed by a norm. Here the punched hole of

the specimen gets expanded by a conical punch as schematically shown in Figure 1.

After a crack has appeared, the hole expansion ratio λ [%] is calculated.

1000

0⋅

−=

D

DDhλ

λ Hole expansion ratio [%]

D0 Start diameter [mm]

Dh End diameter [mm]

(1.1)

Besides the ISO 16630 test, various other tests or test ideas exist. The KWI test was

invented at the “Kaiser Wilhelm Institute” which were reorganised and named “Max-

Planck-Institute” later on. Here a drilled hole is expanded by a flat bottom punch. In

2010, the Salzgitter Mannesmann Forschung (SZMF) introduced its own hole expansion

test version in the frame of the joint project “Sheared Edge Formability” funded by

Stiftung Stahlanwendungsforschung and coordinated by Forschungsvereinigung

Stahlanwendung e.V. In this project, together with the Institute of Institute of Metal

Forming and Metal-Forming Machines (IFUM), Leibniz Universität Hannover, the

SZMF investigates damage and formability of the sheared edge of cold rolled dual-

phase steels. The proposed test combines the hemispheric Nakajima punch from the

FLC test together with a specimen with a punched hole. BMW uses the same tool

geometry with a punched Nakajima specimen in their “BMW Kantenrisstest” [Illig,

2006][ISO 12004-2].

6. Specimen

6.1 Quality of punched edge surface

6.2 Hole position to stamp position

Hole expansion

ISO 16 630Process step 1: PunchingProcess step 2: Expanding

1. Operator 2. Machine

7. Evaluation

3. Tool

2.1 Deviation of the deformation rate

3.4 Wearing of the punching tool

3.2 Geometry of forming die

3.1 Surface conditions (friction) of the forming tool

7.1 Influence of measuring point due

to non-round hole

7.2 Tilt of the

measuring equipment

1.2 Response time

1.1 Different perception of crack-start (switch-off-

criterion)

4. Material

4.1 Homogeneity of

properties

4.2 Sheet thickness

4.3 Mechanical properties(Rp0,2, Rm, A80)

2.2 Direct/ indirect view on the specimen (delay

of image transfer)

2.3 Overrun after stopping the machine

7.3 Technician operation with tactile measuring equipment

5. Procedure

5.1 Punching speed

5.2 Punching conditions (fixing, guidance)

...

... ... ...

... ...

...6. Specimen

6.1 Quality of punched edge surface

6.2 Hole position to stamp position

Hole expansion

ISO 16 630Process step 1: PunchingProcess step 2: Expanding

1. Operator 2. Machine

7. Evaluation

3. Tool

2.1 Deviation of the deformation rate

3.4 Wearing of the punching tool

3.2 Geometry of forming die

3.1 Surface conditions (friction) of the forming tool

7.1 Influence of measuring point due

to non-round hole

7.2 Tilt of the

measuring equipment

1.2 Response time

1.1 Different perception of crack-start (switch-off-

criterion)

4. Material

4.1 Homogeneity of

properties

4.2 Sheet thickness

4.3 Mechanical properties(Rp0,2, Rm, A80)

2.2 Direct/ indirect view on the specimen (delay

of image transfer)

2.3 Overrun after stopping the machine

7.3 Technician operation with tactile measuring equipment

5. Procedure

5.1 Punching speed

5.2 Punching conditions (fixing, guidance)

...

... ... ...

... ...

...

Figure 2; Influences on the results of ISO 16630

Page 3: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

A higher deformation of the edge in comparison to the middle zone can be easily

archived by an optimised punch geometry. [Held et al., 2009] showed the results of a

punch formed like a diabolo toy.

There are many other ideas of loading a blanked edge till the first crack appears [Nitta et

al., 2008][Bouaziz et al., 2010]. Additionally first ideas of using the gathered

information for an estimation of produceability can be found [McEwan et al., 2009].

Thus the ISO 16630 is the only standardised test which valuates the formability of

punched edges and therefore it is surveyed in detail. The influences on the result of an

ISO 16630 test are listed in Figure 2.

2. INFLUENCES ON ISO 16630

Probably the biggest influences as shown in Figure 2 are the punching tool and the

punching process. These influences were analysed but will be not published in this

paper. Here the focus lies on the influences which could be evaluated with the help of

the optical measuring system Aramis [Friebe et al., 2006].

For all following research activities the same batch of hot rolled material with a

thickness of 3.5mm was used. All the specimens were painted before the test for post

analysing with the Aramis system. The punch movement during the test was stopped as

per a normal ISO 16630 test and the λ was recorded.

2.1 Visual perception of the crack There were investigations to use the punch force of an ISO 16630 test as an indicator

for a crack [Dünckelmeyer et al., 2009]. But this method seems to work only on some

steel grades. It is more common, that a technician stops the movement of the punch at

the moment the first crack runs through the complete thickness of the specimen. During

the test the illumination of the specimen and the distance of the technician’s visual line

of sight might not be perfect. Eliminating these secondary effects pictures of the

specimen were taken during the forming by the Aramis system. One of these pictures is

shown in Figure 1b. The pictures were taken with a frequency of 10Hz. ISO 16630

limits the punch velocity to a maximum of 1mm/s which means that the punch moves

maximally 0.1mm from one picture to another. Based on the results of 10 parallel tests

the visual perceptions of 5 different technicians were recorded. This investigation was

split into three cycles as shown in Figure 3.

Cycle Data Emulation

a Real time film sequence Direct view or online video screen

b Chronologic picture to picture Quasistatic testing

c Picture to picture with optional

stepping backwards

Picture grabbing and post analysis

Figure 3; Test order

Page 4: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

The picture numbers taken by the technicians were computed into hole diameters by an

appropriate approximation and afterwards into a hole expansion ratio. The data for the

functions are based on photogrammetric pixel measurements, which allow to detect 3D

points in the Aramis software without any facet-information on the specimens surface

and additionally very close to the edge. The results of the three cycles are shown in

Figure 4. Some scratches in the paint caused some error values but a good portion of the

results show similar detections of cracks. An effect of training or somehow

familiarisation can be seen. With a lower punch velocity (emulated in cycle 2) the crack

had been detected earlier. The last cycle increased this effect. It can be summarised that

the punch velocity or the analysing velocity has an influence on the λ-value but it has no

influence on the deviation of the visual perception of different technicians. Figure 5

shows the scattering inside one cycle and inside one specimen as bar chart of the

standard deviation. It can be pointed out that none of the cycles show significantly

better results.

A scattering value of 10 specimens was generated to visualise the effect of the

technicians influence. The lowest and the highest λ-value of each specimen was

excluded and the mean value was calculated. The scattering of these values can be

understood to be the scattering of the material. The standard deviation of this material

scattering is represented in Figure 5 (horizontal lines). The scattering is large compared

with the characteristic value which ought to be detected.

Result of one technicianSpread of result for one specimen

Mean of the three middle results

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

a b c a b c a b c a b c a b c a b c a b c a b c a b c a b c

1 2 3 4 5 6 7 8 9 10

Number of specimen (1-10) and cycle (a-c)

Ho

le e

xp

an

sio

n r

atio

[%

]H

ole

expansio

nra

tio

[%] 90

80

70

60

50

40

30

20

10

0

Result of one technicianSpread of result for one specimen

Mean of the three middle results

Result of one technicianSpread of result for one specimen

Mean of the three middle results

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

a b c a b c a b c a b c a b c a b c a b c a b c a b c a b c

1 2 3 4 5 6 7 8 9 10

Number of specimen (1-10) and cycle (a-c)

Ho

le e

xp

an

sio

n r

atio

[%

]H

ole

expansio

nra

tio

[%] 90

80

70

60

50

40

30

20

10

0

Figure 4; Results of three cycles of picture analysis

Page 5: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

0

5

10

15

20

25

30

a b c a b c a b c a b c a b c a b c a b c a b c a b c a b c

1 2 3 4 5 6 7 8 9 10

Number of specimen (1-10) and cycle (a-c)

Sta

ndard

devia

tion

of hole

expansio

nra

tio

[%]

Standard deviation of results of 5 technicians

Standard deviation of mean results of the 10 specimen

0

5

10

15

20

25

30

a b c a b c a b c a b c a b c a b c a b c a b c a b c a b c

1 2 3 4 5 6 7 8 9 10

Number of specimen (1-10) and cycle (a-c)

Sta

ndard

devia

tion

of hole

expansio

nra

tio

[%]

Standard deviation of results of 5 technicians

Standard deviation of mean results of the 10 specimen

Figure 5; Scattering among the cycles of the 10 specimens

2.2 Reaction time

Subsection 2.1 identifies the influence of the reaction time at the perception of the crack

as the difference of cycle a (real time) and cycle b (quasistatic). The influence of the

reaction time depends on the hole expansion velocity λ°. Formula 2.1 gives a first

estimation of λ°. The real specimen deforms first to the typical caldera form which

causes a lower λ° at the beginning of the expansion. After that the velocity increases

which was exemplarily measured for one specimen and plotted in Figure 6 as black

dots. The orange dots represent the results of the 10 specimen from subsection 2.1.

0

2

4

6

8

10

12

14

0 20 40 60 80 100

Hole expansion ratio [%]Hole

expansio

nvelo

city

[%/s

]

1 Specimen during forming

10 Specimen at crack timesmm

s

mm

D

D

s

mms

mmv

Dp

%5.11

10

15.1

15.160tan

1

tan

0

==°

=°==°

λ

α

vp Punch

velocity

[mm/s]

α Punch

angle

[°]

D° Hole

diameter

change

[mm/s]

(2.1)a b

0

2

4

6

8

10

12

14

0 20 40 60 80 100

Hole expansion ratio [%]Hole

expansio

nvelo

city

[%/s

]

1 Specimen during forming

10 Specimen at crack timesmm

s

mm

D

D

s

mms

mmv

Dp

%5.11

10

15.1

15.160tan

1

tan

0

==°

=°==°

λ

α

smm

s

mm

D

D

s

mms

mmv

Dp

%5.11

10

15.1

15.160tan

1

tan

0

==°

=°==°

λ

α

vp Punch

velocity

[mm/s]

α Punch

angle

[°]

D° Hole

diameter

change

[mm/s]

(2.1)a b

Figure 6; Hole expansion velocity:

a) approximation b) test results

Page 6: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

These velocities were determined close to the time the crack appears which caused

some lager scattering.

It was described in subsection 2.1 that a lower expansion velocity reduces the influence

of the reaction time and causes a lower mean value of λ. A time or punch travel

dependent expansion velocity might overlie the values of the ISO 16630 results.

A material which is very sensible on punched edge cracking shows cracks at early

stages of the test. Therefore these cracks appear at a lower expansion velocity, which

causes a lower influence of the reaction time and thereby an even lower expansion ratio.

2.3 Effect of online or offline measurement Subsections 2.1 and 2.2 gave an impression of the negative influence of the perception

of the crack on the ISO 16630 results. One improvement might be the decoupling of

forming (or destroying) the specimen and the perception of the crack. This would allow

a quasistatic picture analysis or an automated analysis with an optical measurement

system. If this offline analysis would be realised, the specimen would be measured in a

loaded condition. The λ-value of a loaded specimen should be higher than of the

unloaded specimen due to spring back effects.

Offline Aramis crack detection (loaded)

Gap between offline and online detection of crack (loaded)

Influence of load state (loaded-unloaded)

Tactile measurement of unloaded specimen (unloaded)

18

18

15

11

16

2613

1712

1,7

2,4

1,1

1,4

1,9

2,1 1,5

1,7 2,3

0

10

20

30

40

50

60

70

80

1 2 3 4 5 6 7 8 9

Numer of specimen

Ho

le e

xpansio

nra

tio

[%]

Offline Aramis crack detection (loaded)

Gap between offline and online detection of crack (loaded)

Influence of load state (loaded-unloaded)

Tactile measurement of unloaded specimen (unloaded)

18

18

15

11

16

2613

1712

1,7

2,4

1,1

1,4

1,9

2,1 1,5

1,7 2,3

0

10

20

30

40

50

60

70

80

1 2 3 4 5 6 7 8 9

Numer of specimen

Ho

le e

xpansio

nra

tio

[%]

Figure 7; Influence of load state compared with crack perception

To rate the influence of elastic elongation 9 specimens were treated as fixed in the ISO

standard. The tests were captured by Aramis and analysed afterwards. Based on the

pictures, the technician recognised the crack systematically earlier than his colleague at

the forming press. The gaps between both expansion ratios were up to 26% as shown in

Page 7: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

Figure 7. With the help of the optical measuring system the state of maximal punch

travel and the state of unloading were detected. The change in the expansion ratio was

always lower than 2.4%.

Therefore the influence of the load state can be treated as insignificant which

legitimates an offline analysis of the test.

3. ALTERNATIVES TO THE ISO 16630 PROCEDURE

3.1 Motivation and target As discussed in subsection 2 the ISO 16630 procedure carries some fields for

improvement. Besides the targets listed in Figure 8, an optimisation should aim on the

reduction of the scattering among different technicians. This might be reached with an

abrupt crack initiation and a quick crack growth.

3.2 Adapted KWI test

One alternative procedure to ISO 16630 is the KWI, where the hole should not be

drilled as provided but be punched with a defined blanking clearance. For this operation

the blanking tool for the ISO 16630 specimen can be used. The forming with the flat

bottom KWI punch allows a full analysis with an optical measuring system. A

disadvantage of the flat punch is the insensibility of the burr side. If the testing

procedure should bring up sensitivity on the position of the burr there has to be some

strain gradient through the sheet thickness accordingly at the blanked edge.

Domain Target

Testing facility 1.1 Common testing equipment

Tool for punching 2.1 Standard parts/ tools

Procedure

3.1 Easy to understand

3.2 Robust

3.3 Low time consuming

3.4 Low dependency on technician perception

3.5 Useable for a large variety of steels

3.6 Sheet thickness independent

Analysis 4.1 Low dependency on technician perception

4.2 Possibility for automation (quality check)

Result

5.1 Hole expansion ratio (quality check)

5.2 Comparability between testing institutes

5.2 Main crack direction (anisotropy) (research aspects)

5.3 Strain deviation (anisotropy) (research aspects)

5.4. Time dependent information (research aspects)

Figure 8; Targets for test optimisation

Page 8: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

3.3 Nakajima test with punched hole

Another common tool set is the hemispheric Nakajima punch and adequate die, which is

used for the evaluation of the FLC. A quadratic sheet with a blanked hole in the middle

as the specimen can be formed until the crack appears. The punch geometry causes a

burr side sensitivity but it is also able to cause an inappropriate angle between the

specimen and the camera. If the angle is close to 45° Aramis looses the facets. The

maximal angle a specimen can obtain is constrained by the tested material and the start

diameter. Within the framework of the FOSTA project 830 the dual phase steel grade

HCT780XD was tested at SZMF like proposed above and a start diameter of 20mm was

rated a useful. If the diameter was too large it caused the loss of facets and the opposite

caused holes with a small circumference and therefore less facets. At present there is a

lack of experience to judge the ideal diameter for the test. Nevertheless for the blanking

operation a standard blanking tool set can be used.

3.4 Comparison of three hole expansion tests The results of an ISO 16630 test are already shown in section 2. This is now compared

with the results of a KWI test (with punched hole) and a hole expansion with a

Nakajima punch (all blanked with 12% clearance). The ISO 16630 and the KWI hole

diameter is fixed to 10mm. For the Nakajima test a hole with a diameter of 20mm was

blanked out (in accordance to the FOSTA project 830).

Figure 9 shows the comparison of the determined hole expansion ratios. The mean

value is similar although the gauge length differs (2 different hole diameters). It is

peculiar that the standard deviation of the ISO 16630 results is much higher than the

deviation other two tests. This fact can be consolidated for the tested hot rolled material

concerning the KWI and the ISO 16630 with the internal data base of SZMF. The lower

deviation might be a result of the loading conditions or of a clearer crack start or quicker

growth. Both was seen during the forming of the specimen of Figure 9.

0

10

20

30

40

50

60

70

80

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

KWI Nakajima ISO 16630

Hole

expansio

nra

tio

[%]

Result of 1 specimen

[%]

Standard devation of

expansion ratio [%]

Maximimal expansion

ratio [%]

Minimimal expansion

ratio [%]

Mean expansion ratio

[%]

0

10

20

30

40

50

60

70

80

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

KWI Nakajima ISO 16630

Hole

expansio

nra

tio

[%]

Result of 1 specimen

[%]

Standard devation of

expansion ratio [%]

Maximimal expansion

ratio [%]

Minimimal expansion

ratio [%]

Mean expansion ratio

[%]

Figure 9; Comparison of different hole expansion tests

Page 9: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

After the test the pictures were analysed with Aramis and the punch velocities were

measured. With this information all following expansion velocities were normalised to a

punch velocity of 1mm/s (scattering in the range of 0.9 and 1.2mm/s). To achieve

comparable results all specimens were measured based on the pixel point method even

if the KWI and Nakajima specimens were sprayed with the typical white surface with

black dots. The mean velocity of 3 time sections (5 parallel specimens for each of the 3

test versions) are shown in Figure 10. The ISO 16630 test shows a similar curve

progression and mean value at crack time already determined and presented in Figure 6.

The KWI has the same expansion speed until the crack appears. After that moment the

crack growth is the fastest of the three tests. This crack behaviour enables a punch force

controlled stop criteria for the test, which was positively tested at SZMF. The test

variant with the Nakajima punch shows the same acceleration in the moment of the

crack. Additional to this advantage it also shows a lower expansion speed in the time

section the crack starts. This behaviour allows a detailed analysis of the crack. Although

this low expansion velocity causes a high number of pictures at the state of crack start

the visual perception is very abrupt compared with the ISO 16630. The KWI shows an

even faster crack initiation. A high crack growth is a chance for an explicit perception

and an easier criterion for automated crack detection.

The sensitivity of the burr side, the good expansion velocity behaviour and the use of

standard parts makes the Nakajima test with a blanked hole to be a promising hole

expansion test. Additionally it can be analysed as simply as the ISO 16630 test with a

sliding calliper or for research projects with an optical measurement system.

0

2

4

6

8

10

12

14

16

18

20

From start up to

2s before crack

From 1s before

crack up to the

crack

From crack until

1s afterwards

Hole

exp

ansio

nvelo

city

[%]

KWI

ISO 16630

Nakajima with hole

Lines define the mean values

0

2

4

6

8

10

12

14

16

18

20

0

2

4

6

8

10

12

14

16

18

20

From start up to

2s before crack

From 1s before

crack up to the

crack

From crack until

1s afterwards

Hole

exp

ansio

nvelo

city

[%]

KWI

ISO 16630

Nakajima with hole

Lines define the mean values

KWI

ISO 16630

Nakajima with hole

Lines define the mean values

Figure 10; Expansion velocity of different hole expansion tests

Page 10: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

3.5 Potential of strain measurement at hole expansion

If an hole expansion test is captured by a optical measurement system there are many

possibilities for an offline analysis of the test [Mackensen et al., 2009]. Figure 11a

shows an example. The contour plot gives an impression on the strain on the surface of

the specimen. But it is not usable for a detailed characterisation of one or a comparison

of different materials. For detailed investigations diagrams with some time and place

dependent information about the major strain would be very useful. Figure 11b shows a

diagram which fulfils these requirements. Every curve is the result of a circular section

around the blanked hole. At the beginning of the test all major strains on the circular

section are zero. This state is visualised as a dot (or a circle with radius of 0) in the

middle of the diagram. During the forming the strains increase and form circles or

crosses (regulated by the anisotropy). The time between each circle is one second. If the

radius changes abruptly this is an indication of a crack. For a nearly planar isotropic

material the crack can be indentified very easily. An anisotropic material as shown in

Figure 11b requires a more complex criteria.

Due to the method of operation of Aramis the strain can not be measured direct on the

edge. If the distance to the edge is too small, there is no place for a facet and therefore

no strain information. Here a distance of about 1mm was used to achieve a closed circle

of results.

80

60

40

20

0

20

40

60

80

80 60 40 20 0 20 40 60 80

a b

80

60

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Figure 11; a) Contour plot of major strain

b) Polar diagram of major strain of Nakajima expansion

Page 11: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

4. SUMMARY AND CONCLUSION

The ISO 16630 hole expansion test is the only test focused on the formability of a

punched edge that is fixed by a standard. Unfortunately this test is not completely

satisfactory. The influence of the perception of the crack is a main handicap. To avoid

this influence an offline analysis of the test might be helpful. To gather more

information out of one test a geometry or strain measurement can be useful. An analysis

method is proposed.

In the future, the influences on the new test will be determined following the same

strategy as already done for the ISO 16630 test.

REFERENCES

[Bouaziz et al., 2010] Bouaziz, O.; Douchamps, S.; Durrenberger, L.: “The Double

Bending Test: A Promising New Way for an Optimal Characterization of Cut-

Edges Ductility”; IDDRG2010; Graz; Austria 2010

[Col et al. 2008] Col, A.; Jousserand, P.; „Mechanisms Involved in the Hole Expansion

Test“; IDDRG2008; Olofström; Sweden 2008

[Dünckelmeyer et al., 2009] Dünckelmeyer, M.; Karelova, A.; Krempasky, C.;

Werner, E.; „Instrumented hole expansion test“; Proceedings of International

Doctoral Seminar; Germany 2009

[Friebe et al., 2006] Friebe, H.; Galanulis, K.; Erne, O.; Müller, E.; „FLC

Determination and Forming Analysis by Optical Measurement Systems“;

Proceedings of the FLC; Zürich; Switzerland 2006

[Held et al., 2009] Held, C.; Liewald, M.; Sindel, M.; „Erweiterte

Werkstoffprüfungsverfahren- und Methoden zur Charakterisierung von

Leichtbaublechwerkstoffen in der Umformtechnik“; University of Stuttgart; Audi

AG; Germany 2009

[Illig, 2006] Illig, H. R.; „Analyse der Kantenrissempfindlichkeit“; BMW Group;

Germany 2006

[ISO 12004-2] International Standard ISO 12004-2 „Metallic materials – guidelines for

the determination of forming-limit diagrams“

[ISO 16630] ISO 16630; „Metallic Materials - Method of Hole Expanding Test“;

Technical Specification ISO 16630; Switzerland 2003

Page 12: Investigation on punched edge formability on punched edge formability Matthias Schneider, Uwe Eggers Salzgitter Mannesmann Forschung GmbH Eisenhüttenstrasse 99, 38239 Germany m.schneider@sz.szmf.de,

[McEwan et al., 2009] McEwan, C.; Underhill, R.; Langerak, N.; Botman G.; de

Bruine, M.; „A New approach to predicting edge splits- the combined FLC/HEC

Diagram“; IDDRG2009; Holden; USA 2009

[Merklein et al., 2010] Merklein, M.; Kuppert, A.; Mütze, S.; Geffert, A.; „New Time

Dependent Method for Determination of Forming Limit Curves Applied to

SZBS800“; IDDRG2010; Graz; Austria 2010

[Nitta et al., 2008] Nitta, J.; Yoshida, T.; Hashimoto, K.; Kuriyama,Y.: „Development

of the Practical Evaluation Test and a Study of Numerical Evaluations of Edge

Fracture for Stretch Flangeability of Sheet Metal Forming“; IDDRG2008;

Olofström; Sweden 2008

[Mackensen et al., 2009] Mackensen, A.; Golle, M.; Golle, R.; Hoffmann, H.;

„Determination of the Hole Expansion Properties of AHSS Using an Optical 3D

Deformation System“; IDDRG2009; Holden; USA 2009

ACKNOWLEDGEMENT

The financial support of the Stiftung Stahlanwendungsforschung in the frame of the

joint project “Sheared Edge Formability” coordinated by Forschungsvereinigung

Stahlanwendung e.V. and the collaboration with the Institute of Metal Forming and

Metal-Forming Machines (IFUM), Leibniz Universität Hannover, is gratefully

acknowledged.