Hole expansion test of third generation steels

Abstract

The trend towards the implementation of new materials in the chassis of the automobiles is considerably making more complex the manufacturing of the components that built it up. In this scenario materials with higher strengths and lower formabilities are daily faced by tool makers and component producers what reduces the process windows and makes the forming processes to be in the limits of the materials. One of the concerns that tool makers must face during the definition of the tools is the expansion ratios that the holes in the sheet may reach before producing a breakage due to the stretching of the material (also known as edge cracks). For the characterization of such limits, a standard test, the hole expansion test, can be applied so that the limits of the material are known. At the present study, hole expansion tests of a third generation steel, Fortiform1050 with a thickness of 1.2 millimeters have been carried out and compared them to a mild steel, DX54D with a thickness of 0.6 millimeters. A comparison for each material in terms of technology used to punch the hole, mechanical punching vs laser cutting has also been conducted. In addition, the measurement technique (online measurement vs offline measurement) followed in the Hole Expansion Ratio (HER) identification has also been analyzed. Finally, differences between both materials and techniques are presented.