Fundamentals of Mechanical Engineering Experiments for
Graduate Study
By Numchoak Sabangban
Department of Mechanical Engineering
Khonkaen University 1
Paper topic reviews Role and Importance of Forming Technology of High Strength Steel (HSS) for
Automotive Part Making Industry.
Tribology of Hot Forming Tool and High Strength Steels.
The Study Springback of Advanced High Strength Steel Sheet after Warm and
Hot Forming.
Evaluation of stamping lubricants at various temperature levels using the
ironing test.
Evaluation of stamping lubricants in forming advanced high strength
steels(AHSS) using deep drawing and ironing tests.
Evaluation of stamping lubricants using the deep drawing test.
Investigation of galling in forming galvanized advanced high strength steels
(AHSSs) using the twist compression test (TCT).
Influence of work material proof stress and tool steel microstructure on
galling initiation and critical contact pressure.
Springback prediction in sheet metal forming of high strength steels.
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Introduction
3
Introduction
4
Introduction
5
Introduction
One things to improve this automotive industry is car structure.
6
Introduction
The problem in car structure metal forming.
7
Introduction
Punch
Example during process.
Die
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Tribology of Hot Forming Tool and High
Strength Steels
Authors : Prof. Braham Prakash and Prof. Elisabet Kassfeldt
Method
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Tribology of Hot Forming Tool and High
Strength Steels
Graph and conclusion
•The operating temperature has been shown to influence the friction and wear behaviour of tool steel and UHSS tribo-pairs.
•Generally, friction is reduced at elevated temperatures while wear increases with temperature.
•The most significant contributing wear mechanisms are adhesive and abrasive wear.
•Plasma nitriding of the tool steel is effective in reducing friction and wear at elevated temperatures and provides
protection against severe adhesive wear (i.e. galling).
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The Study Springback of Advanced High
Strength Steel Sheet after Warm and Hot
Forming
Authors : Phaisin Jaitiang and Dilok Sriprapai
Method and materials : using HSS (SPFC 980Y)
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The Study Springback of Advanced High
Strength Steel Sheet after Warm and Hot
Forming
Graph
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The Study Springback of Advanced High
Strength Steel Sheet after Warm and Hot
Forming
Conclusion
• At high temperature was cause to reduce springback.
• When temperate to 900 C was not have springback.
• During temperature around 700 C the materials
hardness reduce to 19.65 %.
• The surface oxide can observe when temperature
higher 500 C.
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Evaluation of stamping lubricants at various
temperature levels using the ironing test
Authors : Shrinidhi Chandrasekharana, Hariharasudhan Palaniswamya,Nitin
Jaina, Gracious Ngaileb, Taylan Altana
Method and materials : Improve the materials flow into the die, reduce wear
and galling in the die and obtain good finish the part by simulation and
experiment by using material AKDQ.
Evaluate : Lub and temperature
reach to 200 C.
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Evaluation of stamping lubricants at various
temperature levels using the ironing test
Graph
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Evaluation of stamping lubricants at various
temperature levels using the ironing test
Conclusion
At both room temperature and elevated temperature, Lub B (the zinc
phosphate coating + sodium soap),performed best followed by Lub A (the dry
film) and Lub E (pre-emulsified with solid lubricant), while the emulsions
failed (scratching and galling) due to the high interface pressures.
When starting process in FEM the friction factor was higher because the
contact of material is metal to metal.
The reduction ratio at elevated temperatures is smaller than that at room
temperature. A new ironing ring, which compensates for thermal expansion
may need to be designed.
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Evaluation of stamping lubricants in forming
advanced high strength steels (AHSS) using
deep drawing and ironing tests Authors : Hyunok Kim, Taylan Altan and Quingguang Yan .
Materials and method : Using HSS(DP 690) to evaluate performance of
lubricant in the DD and ironing process by using FEM and experiment.
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Evaluation of stamping lubricants in forming
advanced high strength steels (AHSS) using
deep drawing and ironing tests
Graph
18
Evaluation of stamping lubricants in forming
advanced high strength steels (AHSS) using
deep drawing and ironing testsConclusion
Based on performance evaluation criteria used in deep drawing and ironing
tests, Lubricants type Polymer-based lubricant with EP additive which the
best performance to this process.
The FE will predict the black contact pressure in the blank holder to evaluate
the performance of lubricant in the exit of production.
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Evaluation of stamping lubricants using
the deep drawing test
Authors : Hyunok Kim, Ji Hyun Sung, Rajesh Sivakumar and Taylan Altan.
Material and method : Using 5 Lubricant (A, B, C, D and E)
In this research will evaluate the
performance of lubricant to find the
minimum friction and successful drawing.
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Evaluation of stamping lubricants using
the deep drawing test
Graph and discussion
• Based on various evaluation criteria, Lub A
was most effective regardless of testing
speeds and BHFs.
• Lub A may be a good lubricant for most
severe deep drawing conditions. However,
Lubes B and C were relatively effective for
use in moderate deep drawing conditions.
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Investigation of galling in forming galvanized advanced
high strength steels (AHSSs) using the twist compression
test (TCT)
Authors : Hyunok Kima, Jihyun Sunga, Frank E. Goodwinb and Taylan Altan.
Materials and method : Using materials DP500, 600, AKDQ and DDS to twist
compression test and FE to find the performance of different galvanize
coating and lubricant to find the galling effect.
22
Investigation of galling in forming galvanized advanced
high strength steels (AHSSs) using the twist compression
test (TCT)
Graph
23
Investigation of galling in forming galvanized advanced
high strength steels (AHSSs) using the twist compression
test (TCT)
Conclusion
At 100 MPa, DP600 with Lub A showed moderate galling and 170 MPa Lub B
showed the best effectiveness in reduction galling.
Lub B showed less powdering (i.e. zinc coating and carbon residue) than Lub A
for most galvanized coatings, however AKDQ HDGA showed less powdering
with Lub A at 170MPa.
the maximum temperature at the tool – workpiece interface was not found to
be very severe to decrease the lubricant viscosity.
The galling cause to powdering and COF. It’s important to surface finish with
acceptable range to prevent any ploughing effect of the contact area.
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Behavior of high strength structural
steel at elevated temperatures
Authors : J. Chen, B. Young and B. Uy
Materials and method : Using HSS ASTM A514 (DP 690) to find mechanical
properties (such as yield and ultimate tensile strength) by using tensile test
and varying temperature.
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Behavior of high strength structural
steel at elevated temperaturesGraph and conclusion.
The temperature was cause to change mechanical properties of materials
from 400 C or higher with the exponential curve.
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Influence of work material proof stress and tool steel
microstructure on galling initiation and critical contact
pressure
Authors : Patrik Karlsson n, PavelKrakhmalev, AndersGaard and JensBergstrom
Materials and method : Using stainless steel to specimen and used IC (ingot
cast) and PM (Powder metallurgy) to tool materials, and predict galling form
chemical position by proof stress and contact pressure. Experiment by pin on
disc and FEA to verify ( galling = P > Pf )
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Influence of work material proof stress and tool steel
microstructure on galling initiation and critical contact
pressure
Graph and conclusions
If tests run at P > Pcr , galling was detected
within the selected distances, while for tests
run at P < Pcr , galling was not observed.
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Springback prediction in sheet metal
forming of high strength steels
Authors : B. Chongthairungruang, V. Uthaisangsuk, S. Suranuntchai and
S.Jirathearanat
Materials and method : Using AHSS (JSC590R and JSC780Y) to find the springback by
U – shape bending test in FEM and find materials properties by tension and
compression cyclic test .
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Springback prediction in sheet metal
forming of high strength steels
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Springback prediction in sheet metal
forming of high strength steelsGraph and conclusions
The cyclic test was successfully performed for determining
materials parameters of the kinematic model. The pre-strains
between 9 and 11 percent.
The differences of stress distributions on the top and bottom
surface of the formed samples significantly affected the
sidewall curl, in particular the high strength steels. The AHS
steel exhibited very large range of the elastic strain recovery.
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Thanks for attentions
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References
Vitoon Uthaisangsuk.(2013). Role and Importance of Forming Technology of High Strength Steel (HSS) for Automotive Part
Making Industry. Guideline for forming Advance High strength Steels, December 2013.
Jens Hardell., Braham Prakash., and Elisabet Kassfeldt. Tribology of Hot Forming Tool and High Strength Steels. Lulea
University of technology.
Phaisin Jaitiang., and Dilok Sriprapai. The Study Springback of Advanced High Strength Steel Sheet after Warm and Hot
Forming.
Chandrasekharan, S., Palaniswamy, H., Jain, N., Ngaile, G., and Altan, T. (2005). Evaluation of stamping lubricants at various
temperature levels using the ironing test. International Journal of Machine Tools and Manufacture, vol.45(4-5), pp.379-388.
Kim, H., Altan, T., and Yan, Q. (2009). Evaluation of stamping lubricants in forming advanced high strength steels (AHSS) using
deep drawing and ironing tests. Journal of Materials Processing Technology, vol.209(8), pp. 4122-4133.
Kim, H., Altan, T., and Yan, Q. (2007). Evaluation of stamping lubricants using deep drawing and ironing tests. International
Journal of Machine tools and manufracture, vol.47(8), pp. 2120-2132.
Kim, H., Altan, T., Sung, J., and E.Goodwin, F. (2008). Investigation of galling in forming galvanized advanced high strength
steels (AHSSs) using the twist compression test (TCT). Journal of Materials Processing Technology, vol.205(10), pp. 459-468.
Chen, J., Young, B., and Uy, B. (2006). Behavior of high strength structural steel at elevated temperatures. Journal of
Structural Engineering, vol.132(12), pp. 1948-1954.
Karlsson, P., Krankhmalev, P., Gaard, A., and Bergstorm, J. (2013). Influence of work material proof stress and tool steel
microstructure on galling initiation and critical contact pressure. Journal of Tribology International, vol.60(7), pp. 104-110.
Chongthairungruang, B., Uthaisangsuk, V., Suranuntchai, S., and Jirathearanat, S. (2013). Springback prediction in sheet metal
forming of high strength steels. Journal of Materials and design, vol.50(14), pp. 253-266.
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