Beruflich Dokumente
Kultur Dokumente
IMPROVEMENTS
Mike Shih
United States Steel Corporation
www.autosteel.org
www.autosteel.org
Outline
Introduction
Optimized Bevel Shear Hole Piercing
Conclusions
www.autosteel.org
Introduction
Shearing Processes
Blank Holder
Punch
Punch
Sheet Metal
Die
Clearance
Clearance
Upper Blade
Front View
Blank Holder
Sheet Metal
Lower Blade
Q1
www.autosteel.org
Punch
6 degrees
Clearance
Die
Dd
Sheet Steel
Pd
Punch
Holder
Die spring
www.autosteel.org
Punch
Shear Load
7000
3-L
3-T
6000
6-L
5000
6-T
9-L
4000
9-T
3000
2000
1000
0
8%
13%
17%
Die Clearance
www.autosteel.org
21%
60%
flat
6-T
3-L
9-L
3-T
9-T
50%
40%
30%
20%
10%
0%
10%
15%
Die Clearance
www.autosteel.org
20%
6-L
50%
DP980 1.2 mm
DP980 2 mm
40%
30%
20%
10%
0%
5%
7%
9%
11%
13%
15%
www.autosteel.org
17%
19%
50XK 1.4mm
50XK-F
100.0%
50XK-6L
Dp600-2mm-F
DP600 2mm
80.0%
40%
DP780 (1mm)
Trip780 (1.6mm)
60.0%
40.0%
20.0%
DP600-2mm-6L
23%
F
F
DP980 2mm
62%
Dp780-1mm-F
DP780-1mm-6L
TRIP780-1.6mm-F
TRIP780-1.6mm-6L
Dp980-2mm-F
25%
39%
0.0%
1
Test Material
www.autosteel.org
Dp980-2mm-6L
Concept Punch
6 degrees
Concept 2 : 9C
50XK
140.0%
Concept 2 : 6C
Concept 1 : 6-6
Optimized : 6L
9 degrees
6 degrees
6 degrees
120.0%
100.0%
60.0%
40.0%
20.0%
DP600 2 mm
DP600 1.6 mm
DP600 1mm
80.0%
6-6
6L
6-6
F
F
6L
6L
6L
0.0%
50XK- 50XK- 50XK- 50XK- 600F
6L
6C
9C
1-F
6001.66C
Punch Condition
www.autosteel.org
6001.69C
6002-F
6002-66
Rollover
Burnish
Burnish
Initial Contact
Point
Final Contact
Point
Fracture
(1)
(2)
Section cut
(2)
Rolling
Fracture
Bevel
Shear
Rollover
(%)
Burnish
(%)
Fracture
(%)
Side 1
12
21
68
HER
(%)
53
Side 2
360
13
13
380
Typical
340
320
Optimized
Conventional
Optimized
Flat
Head
Rollover
(%)
Burnish
(%)
Fracture
(%)
Side 1
16
21
63
Side 2
16
21
63
1/2 Fracture
Typical
360
340
Optimized
Conventional
Optimized
320
HV
300
HV
(1)
280
260
300
280
260
240
240
220
220
200
200
0
100
200
300
400
500
600
700
800
HER
(%)
32
74
1/2 Burnish
(2)
(1)
100
200
300
400
500
www.autosteel.org
600
700
800
Upper Blade
Holding Pad
Sheet Metal
Lower Blade Rake Angle Q1
Lower Blade
Die Clearance
Front View
www.autosteel.org
Upper Blade
Lower Blade
www.autosteel.org
Curve
Q3 <= 3 degrees
Q3 = 2 degrees
Q3 = 1 degree
www.autosteel.org
20
001
002
003
004
15
10
1 degree
Q3
3 degrees
78% load drop
19% energy drop
2 degrees
67% load drop
22% energy drop
4 degrees
0
4
10
12
14
16
Displacement (mm)
www.autosteel.org
18
Transverse Shearing
Longitudinal Shearing
Sheet Metal
www.autosteel.org
Sheet Metal
1400
363-10%
363-15%
363-20%
1300
363-L
363-T
1350
1200
1100
1300
1250
1200
1150
1100
700
1050
600
1000
0
Time (Sec)
www.autosteel.org
Time (Sec)
Sheared Edge
www.autosteel.org
8% improvement
TE (%)
27
26
25
24
23
22
CV
JIS
333
363
393
633
663
693
Shearing Condition
Conventional
Shearing
JSTM
Milled
www.autosteel.org
933
963
993
As-sheared
edge
Localized
Necking
Fracture
initiation
Type (4)
As-sheared
edge
Tensile failure +
Localized Necking
Fracture
Type (3)
As-sheared
edge
Edge crack +
Tensile failure
Fracture
Type (2)
www.autosteel.org
As-sheared
edge
Tensile failure
Fracture
Type (1)
10%
15%
27
TE (%)
20%
25
23
21
19
333
363
393
633
663
693
933
Shearing Conditions
www.autosteel.org
963
993
Edge Fracture
www.autosteel.org
50
10%
15%
45
20%
40
35
30
25
333
363
393
633
663
693
933
Shearing Condition
www.autosteel.org
963
993
40%
Fracture Strain
35%
10%
15%
30%
20%
25%
20%
15%
10%
5%
0%
333
363
393
633
663
693
933
Shearing Condition
www.autosteel.org
963
993
Criterion
The first through-thickness crack at the edge
The onset of local necking
24
Ao A f
Ao
DP980 1.2 mm
333
363
22
20
18
16
14
12
10
10
SELS
15
www.autosteel.org
20
q
100
1 q
Conclusions
The experiments confirmed that the use of the optimal hole shearing condition can result in
significantly better edge stretchability for all AHSS.
A computer controlled adjustable straight edge shearing device was successfully developed
based on the findings from the beveled shear hole piercing process.
The maximum shearing force and applied energy can be significantly reduced when proper shear
variables are used during shearing.
The shearing force also depends upon the die clearance, and the larger die clearance tends to
the decrease the shear force.
The sheared edge tension test and dome test confirmed that the optimal setup of the rake
angles in the straight edge shearing process would result in a significant improvement of edge
stretchability for test AHSS.
The optimal shearing condition for AHSS is using the rake angle setup (3,6,3) with 15% die
clearance.
www.autosteel.org
www.autosteel.org
w w w . a u t o s t e e l . o r g
www.autosteel.org