68 Journal of Modern Mechanical Engineering and Technology, 2014, 1, 68-74

Defects and Remedies in Stamping of Advanced High Strength

Steels

Ilyas Kacar1, Fahrettin Ozturk2,* and Firas Jarrar2

1
Department of Mechanical Engineering, Nigde University, Nigde, Turkey
2
Department of Mechanical Engineering, The Petroleum Institute, Abu Dhabi, UAE
Abstract: In recent years, the use of advanced high strength steels (AHSS) in the automotive industry has increased
due to their potential in reducing weight, leading to lower fuel consumption and carbon dioxide emissions. The AHSS
structures would be the optimum choice for many applications; however, there are many defects to overcome in their
stamping. In this present study, different types of defects and remedies of AHSS stampings are presented.

Keywords: Advanced high strength steel, AHSS, Failure analysis, Damage behavior of multiphase steels, Failure
prediction.

1. INTRODUCTION sacrificing the safety requirements. Figure 1 compares

the percent elongation to failure and yield strength
Lightweight materials, such as composites, values of different grades of steels. Steels in the AHSS
aluminum, and magnesium alloys are commonly used
family are under continuous development and include
in the automotive and aerospace industries. However,
Dual Phase (DP), Transformation-Induced Plasticity
when lower density materials (such as Al and Mg
(TRIP), Twinning-Induced Plasticity (TWIP), Martensitic
alloys) are used, thicker parts are required to
(MS or MART), Complex Phase (CP), Ferritic Bainitic
compensate for their lower strength. In addition, there
(FB), and Hot Formed (HF). Examples of some AHSS
are some difficulties in the cold forming of such low-
and their mechanical properties are listed in Table 1.
density alloys. After the oil crisis in the 1970s, the steel
industry has started to develop the dual-phase (DP) Dual phase steels are characterized by their
steels (ferritic-martensitic) in order to decrease fuel
microstructure where hard martensite grains are
consumption and exhaust tail pipe emissions. DP
dispersed. Martensite grains provide high strength in
steels are part of broader type of steels which are
the soft and ductile structure of the ferritic matrix. The
known as advanced high strength steels. These AHSS
strength is adjusted by the amount of martensite and
offer up to five times the strength relative to the mild
carbon content. DP steels exhibit a high hardening
steels. Therefore, they can be an attractive alternative
exponent, low UTS/YS ratio (around 0.5) and a high
to lightweight materials in achieving lightweight
structuring. Obviously, AHSS are not considered to be tensile strength. In addition, their energy absorption
lightweight materials, however; due to their high yield capability is relatively good. Transformation induced
strength, the sheet thicknesses can be significantly plasticity steels are characterized by a good
reduced and consequently weight reduction can be combination of strength and ductility and have a
achieved. Advanced high strength steel tubes are microstructure containing retained austenite in a ferrite
currently used as side impact door beams, seat matrix and hard phases like bainite and martensite.
structures, and instrument panel beams in automobiles Complex phase steels, as the name suggests, contain
[1]. AHSS have been being increasingly used in more than one phase. The minimum yield and tensile
automobile structural components due to their strengths of CP steels are 360 MPa and 1130 MPa,
corrosion resistance, toughness, and high resistance to respectively. Complex phase steels are treated as a
impact. In specific, Martensitic Steels (MS) are typically transition from DP to ultra-high strength steels.
used to provide collision protection by minimizing the
deformation from sideward impacts [2]. A more Only few studies can be found dealing with the
extensive use of AHSS in the automotive industry defects encountered during sheet metal forming of
would cause a significant reduction in weight without AHSS. In this paper, we have focused on certain
failures (and their remedies) encountered during sheet
forming of the different grades of advanced high
*Address correspondence to this author at the Department of Mechanical strength steels.
Engineering, The Petroleum Institute, Abu Dhabi, UAE; Tel: +971 2 607 5197;
Fax: +971 2 607 5200; E-mail: [email protected]

E-ISSN: 2409-9848/14 © 2014 Avanti Publishers

Defects and Remedies in Stamping of Advanced High Strength Journal of Modern Mechanical Engineering and Technology, 2014, Vol. 1, No. 2 69

Figure 1: Comparison of the elongation and yield strength values of different grades of steels [3, 4].

Table 1: The Mechanical Characteristics of some AHSS

Grade Yield Stress Tensile Strength Elongation

Rp (MPa) Rm (MPa) (%) min

DPXXX [5] 1237 1431 14.2 (A20)

CPXXX [6] 600-750 780-950 ≥ 10 (A 80)
MSXXX [1] 1150 1400-1600 ≥ 3 (A80)

2. FORMING OF ADVANCED HIGH STRENGTH strength, formability, energy absorption and durability.
STEEL SHEETS However, in the different manufacturing processes that
are available, the sheet forming of AHSS is still
Automotive steel parts are subjected to dynamic
considered difficult. There have been numerous studies
loading from road conditions. The current trend, in
on AHSS both experimentally and numerically such as
addition to lightweight structuring, is to use materials
the sheet forming of TRIP steels [7], Al-alloyed TRIP
that are strong, resistive to cracks under cyclic loading, [8], DP600, M900, DP980 [9], and M1310 [10,11]. DP
and easy to form. Stamping techniques are often used
steels, which cover a considerable portion of the AHSS
to perform successful forming of complex automotive
applications, have enough ductility for the forming
body panels. Figure 2 shows stamping processes such
operations although they have a large work hardening
as hot stamping and a deep drawing. Mild steels have
behavior. Therefore, currently, the DP steels are
excellent formability (e.g. for deep drawing), and high preferable, among the AHSS, for stamping processes.
strength steels (HSS) have a good balance among

Figure 2: A typical hot stamping and deep drawing processes [12, 13].
70 Journal of Modern Mechanical Engineering and Technology, 2014, Vol. 1, No. 2 Kacar et al.

Table 2: Constitutive Relations of some DP, TRIP, and HSLA Steels

Material Constitutive Equation (MPa) Anisotropy

0.169
DP600 [14] σ = 1008ε r0° = 0.73; r 45° = 0.9; r 90° = 0.93

From tensile test

0.208
σ = 1444ε
TRIP780 [15] r0° = 0.802; r45° = 0.9; r90° = 0.874 [16]
From bulge test
0.183
σ = 1554ε
0.09
DP-1000 [17] σ = 1521ε r0° = 0.75; r 45° = 0.9; r 90° = 0.77
0.14
HSLA 350/450 [17] σ = 807ε r0° = 1.1
0.24
TRIP 450/800 σ = 1690ε r0° = 0.9

$ 0.686 + 1.044 " '

HSLA 410 [18] ! = 592 & #995 " ) r0° = 0.559 [19]
&% # (1 # 109000" ) e
2
)(

3. DEFECT TYPES AND REMEDIES Some simple shaped AHSS parts (such as side
impact beams) can be formed by cold stamping with
In stamping of AHSS, the occurrence of defects stresses reaching up to 1200 MPa [21]. There are no
depends on various factors such as the material type (n heating and cooling costs in cold forming but these
and R-values), geometry (sheet thickness, tooling steels have limited formability and significant
shapes), press speed (ram speed), temperature, and springback at room temperature and warm forming
lubrication. Almost all of these parameters are conditions. Springback causes geometrical deviation
interdependent. The relationship between the effective from desired shape and leads to alignment problems
stress and effective strain can be stated by a between parts while mounting. The blank holder force
constitutive equation that models the material (BHF) is one of the main parameters affecting
mechanical behavior. Table 2 summaries some of the springback. Accumulation of local deformations causes
materials models used in literature. Determining the fracture fails when maximum BHF is exceeded in
best fit is still a challenging topic. bending. This effect can be minimized by using
lubricants. Various lubricants have significant effects on
Tension test data are not enough to model the
the total springback. Fracture mechanics gives a
material behaviour of sheet materials under biaxial
comprehensive sense of lubricant film disruption limits
forming conditions. While a material in tensile test may
under high contact pressure as seen in Figure 4.
fail at 15% elongation, it may fail at an elongation of
Springback reduction is also possible by using very
40% in bending. The dome height at fracture (bursting)
small tool radii.
in the viscous pressure bulge test can be used as a
measure of formability as seen in Figure 3.

Figure 4: Deep drawing tests for DP steel with different

Figure 3: The post-uniform deformation capability [20]. lubricants [22].
Defects and Remedies in Stamping of Advanced High Strength Journal of Modern Mechanical Engineering and Technology, 2014, Vol. 1, No. 2 71

Over forming is a known solution for springback Splitting (tearing) is another defect type present in
which is based on providing compensation in the the forming of AHSS from necking that starts from
springback angle. Bottoming is another solution done critical levels of strain. Wrinkling is owing to folding
by reducing the stress in previously bended sections. which occurs due to insufficient constraints. When the
Neither over forming nor bottoming is needed in hot locations and heights of draw beads are not designed
stamping processes to eliminate the springback. properly and an improper BHF is applied, deformation
Springback disappears because heating lowers the restriction on the punch head is not sufficient to provide
material’s yield point. For the same deformation the required stretching. Drawbeads and binders are
conditions, springback increases with decreasing the used to control material flow to obtain uniform
modulus of elasticity, E, and increasing the yield deformation. While the blank in front of the punch is
strength of a material. It is seen in Figure 5 that pulled towards the die line, compressive stresses are
springback is eliminated in the hot forming of AHSS created in the circumferential direction due to the
blanks. Shielding gases, in hot forming, are required to circumference reduction and the tensile stresses in the
axial direction. If compressive stresses are excessive, it
prevent the contact between the material and air in the
causes wrinkling. Figure 6 shows splitting in DP during
atmosphere thus it leads to avoid the scale layer or
cross-die deforming. A remedy for both (splitting and
oxidation which causes worsening of the mechanical
wrinkling) is to apply the proper BHF. In Figure 7, the
properties into a more stiff and fragile structure. It is
optimum BHF to evade from wrinkling is about 1.62
worth mentioning that protective coatings like Al-Si on
MPa [3]. When BHF exceeds this critical level, cracks
22MnB5 can be applied before heating to prevent
occur and affect the part quality.
oxidation.
In hot stamping conditions, BHF requirements are
going to be smaller due to softening at elevated
temperatures. When the heat loss is faster, the
required BHF will increase, as seen in Figure 8.

Wear on die-punch surfaces is another parameter

that affects the stamping process. Design
considerations can make serious improvements as
seen in Figure 9. Various parameters such as the sheet
material and thickness, punch material and coating,
punch-die clearance, punch velocity, and punch/die
corner radii influence the punch-die life. Coating
provides up to 10 times longer life, compared to
uncoated tools. Such coatings are generally applied on
cutting tools using chemical or physical vapor
Figure 5: Springback for hot-cold deformation conditions deposition.
[23].

Figure 6: Splitting [24] and wrinkling in DP.

72 Journal of Modern Mechanical Engineering and Technology, 2014, Vol. 1, No. 2 Kacar et al.

Figure 9: Bigger punch radius leads to longer tool life [27].

Figure 7: Height of wrinkle becomes bigger when the applied
BHF decreases [25].
Although the forming limit diagram for most metals
is a useful method to determine the limit of safe zones,
prediction of crack initiation and propagation is not so
easy for AHSS. When the fracture shapes are
examined it is seen that most cracks are in mode 3
type and unpredictable except for frictionless dome
tests of some TRIP and DP steels as seen in Figure
10. Both can exhibit mode 1 type fracture and this can
be predicted partially. Stress concentrations and local
exceessive deformations are responsible for those
unpredicted failures during stretch bending and
flanging.

The different resistances to thinning in different

directions of the sheet metal leads to non-uniform flows
Figure 8: Relationship between heat-transfer coefficient and during deformation. Earing arises from unequal
BHF [26]. deformation due to planar anisotropy. Planar

(a) (b)

(c) Underbody structural part and B-pillar inner

Figure 10: Fracture propagation shapes due to over BHF in deep drawing for (a) HSLA and (b) TRIP and (c) DP steels [28].
Defects and Remedies in Stamping of Advanced High Strength Journal of Modern Mechanical Engineering and Technology, 2014, Vol. 1, No. 2 73

Figure 11: Earing and fail in DP before process is completed [29].

anisotropy is 0.33 in TRIP while 0.001 in DP, so (UMTIK 2014) and published in the Conference
stamping process exhibits higher earing in TRIP sheet Proceedings. Conference Organizing Committee gave
[15]. Non-uniform material flow around the blank the permission to submit the paper to a recognized
circumference results in shear cracks in latitudinal journal. Then the paper was restructured and revised
direction in DP steel as seen in Figure 11. significantly prior to journal publication.

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Received on 11-11-2014 Accepted on 22-11-2014 Published on 23-01-2015

DOI: http://dx.doi.org/10.15377/2409-9848.2014.01.02.4

© 2014 Kacar et al.; Avanti Publishers.

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