Using Strain Hardening for Advanced Structural Analysis Quality of Vehicle Components

In the automotive industry the topic of lightweight is continuously updated. Especially for crash-relevant parts there is still a high potential for decreasing the weight. There are high requirements for sheet metal parts in crash area. So there is a conflict in reducing the thickness of the sheets and still meeting those requirements. For this reason new high-strength steels are developed with high formability and a high potential of strain-hardening. This means that the materials strength will increase during the forming process. So the product-developer can use a lower thickness but also reach the needed strength.

To consider this property in the development of sheet metal products the amount of strain-hardening caused by the forming process has to be estimated in a forming simulation. Then the results can be mapped on a FE-Modell for further structural analysis.

There are two kinds of forming simulations, the inverse one step method and an incremental method. The second one represents the process in several steps and requires input data about the process parameters and tools. The first method represents the process with one step and only requires some data about the material and part geometry. It is easier and faster and so the forming results can be provided quickly.  But it is less accurate. For this reason the results quality of the one step method will be analyzed in comparison to the incremental method.

The Author

Jasmin Brühmann
Working Student
Kirchhoff Automotive

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