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Materials 2016, 9(2), 77; doi:10.3390/ma9020077

Deep Drawing of High-Strength Tailored Blanks by Using Tailored Tools

Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund 44227, Germany
Current address: AutoForm Engineering Deutschland GmbH, Dortmund 44227, Germany (since 1 December 2015).
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Academic Editor: Richard Thackray
Received: 27 November 2015 / Revised: 12 January 2016 / Accepted: 19 January 2016 / Published: 27 January 2016
(This article belongs to the Special Issue Forming of Light Weight Materials)
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Abstract

In most forming processes based on tailored blanks, the tool material remains the same as that of sheet metal blanks without tailored properties. A novel concept of lightweight construction for deep drawing tools is presented in this work to improve the forming behavior of tailored blanks. The investigations presented here deal with the forming of tailored blanks of dissimilar strengths using tailored dies made of two different materials. In the area of the steel blank with higher strength, typical tool steel is used. In the area of the low-strength steel, a hybrid tool made out of a polymer and a fiber-reinforced surface replaces the steel half. Cylindrical cups of DP600/HX300LAD are formed and analyzed regarding their formability. The use of two different halves of tool materials shows improved blank thickness distribution, weld-line movement and pressure distribution compared to the use of two steel halves. An improvement in strain distribution is also observed by the inclusion of springs in the polymer side of tools, which is implemented to control the material flow in the die. Furthermore, a reduction in tool weight of approximately 75% can be achieved by using this technique. An accurate finite element modeling strategy is developed to analyze the problem numerically and is verified experimentally for the cylindrical cup. This strategy is then applied to investigate the thickness distribution and weld-line movement for a complex geometry, and its transferability is validated. The inclusion of springs in the hybrid tool leads to better material flow, which results in reduction of weld-line movement by around 60%, leading to more uniform thickness distribution. View Full-Text
Keywords: tailored blanks; hybrid deep drawing tools; high strength steels; tailored tools tailored blanks; hybrid deep drawing tools; high strength steels; tailored tools
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Mennecart, T.; ul Hassan, H.; Güner, A.; Ben Khalifa, N.; Hosseini, M. Deep Drawing of High-Strength Tailored Blanks by Using Tailored Tools. Materials 2016, 9, 77.

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