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Metals 2018, 8(8), 631;

Modeling of Forming Limit Bands for Strain-Based Failure-Analysis of Ultra-High-Strength Steels

Institute of Applied Mechanics, RWTH Aachen University, Mies-van-der-Rohe-Str. 1, 52074 Aachen, Germany
Ford Werke GmbH, Research and Innovation Center Aachen, Suesterfeldstrasse 200, 52072 Aachen, Germany
This paper is an extended version of paper published in the 21st International ESAFORM Conference on Material Forming: ESAFORM 2018, Palermo, Italy, 23–25 April 2018.
Author to whom correspondence should be addressed.
Received: 9 July 2018 / Revised: 6 August 2018 / Accepted: 7 August 2018 / Published: 10 August 2018
(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)
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Increased passenger safety and emission control are two of the main driving forces in the automotive industry for the development of light weight constructions. For increased strength to weight ratio, ultra-high-strength steels (UHSSs) are used in car body structures. Prediction of failure in such sheet metals is of high significance in the simulation of car crashes to avoid additional costs and fatalities. However, a disadvantage of this class of metals is a pronounced scatter in their material properties due to e.g., the manufacturing processes. In this work, a robust numerical model is developed in order to take the scatter into account in the prediction of the failure in manganese boron steel (22MnB5). To this end, the underlying material properties which determine the shapes of forming limit curves (FLCs) are obtained from experiments. A modified Marciniak–Kuczynski model is applied to determine the failure limits. By using a statistical approach, the material scatter is quantified in terms of two limiting hardening relations. Finally, the numerical solution obtained from simulations is verified experimentally. By generation of the so called forming limit bands (FLBs), the dispersion of limit strains is captured within the bounds of forming limits instead of a single FLC. In this way, the FLBs separate the whole region into safe, necking and failed zones. View Full-Text
Keywords: forming limit curve; inhomogeneity; boron steel; robustness evaluation forming limit curve; inhomogeneity; boron steel; robustness evaluation

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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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Bayat, H.R.; Sarkar, S.; Anantharamaiah, B.; Italiano, F.; Bach, A.; Tharani, S.; Wulfinghoff, S.; Reese, S. Modeling of Forming Limit Bands for Strain-Based Failure-Analysis of Ultra-High-Strength Steels. Metals 2018, 8, 631.

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