Study on design of progressive dies for manufacture of automobile structural member using DP980 advanced high strength steel

• Published in: Journal of mechanical science and technology Vol. 30; no. 2; pp. 853 - 864
• Main Authors: Lee, Eun-Mi, Shim, Do-Sik, Son, Jong-Youn, Baek, Gyeong-Yun, Yoon, Hi-Seak, Ro, Kyoung-Bo
• Format: Journal Article
• Language: English
• Published: Seoul Korean Society of Mechanical Engineers 01.02.2016; Springer Nature B.V; 대한기계학회
• Subjects: Accuracy; Automobile industry; Automobiles; Automotive components; Automotive engineering; Automotive parts; Compensation; Computer simulation; Control; Crashworthiness; Duplex stainless steels; Dynamical Systems; Engineering; Finite element method; Forming; Fuel consumption; High strength steels; Impact strength; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Metal forming; Metal sheets; Optimization; Parameter optimization; Progressive dies; Springback; Structural members; Structural steels; Taguchi methods; Vibration; Weight reduction; 기계공학; Advanced high-strength steel (AHSS); FE simulation; DP980; Springback; Taguchi method
• ISSN: 1738-494X; 1976-3824
• DOI: 10.1007/s12206-016-0140-7

Advanced high-strength steel (AHSS) is widely used in automobile manufacturing to reduce the weight of vehicles, thereby improving fuel efficiency. However, the high yield and tensile strength of AHSS leads to a serious springback problem in the cold sheet metal forming process. This phenomenon has delayed the implementation of AHSS in vehicle parts due to the resulting negative impact on part accuracy. In this study, parameter optimization and multi-stage die compensation were conducted with Finite element (FE) analysis to develop a progressive forming process for automobile structural members using DP980. The FE simulation used the Yoshida-Uemori model to predict the springback phenomenon accurately. The key parameters that significantly influence the springback behavior were optimized using FE simulation and the Taguchi method. The simulation results were used to determine the die and mold compensation. After the parameter optimization and multi-stage die compensation, the final part was obtained with acceptable dimensional accuracy.