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1, USA R&D Center, Arcelor Mittal Steel
2, Riviera Tool Company

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Better formability More springback

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Shape Deviation: Springback + Twist + Geometry Constraint

Systematic study: Break problem down into basic elements

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Pure
Springback springback

Curl

Springback Mode Tooling Deformation

Angular Springback Punch Bending + T
Sidewall Curl Die Bending & Unbending + T
Flange Curl & angle Drawbead Bending & Reverse bending + T

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Comparison of Springback Angle (1.60mm)

30.0

EDDS
HS440
HSLA350
DP600
Springback (degree)

DP980

Angular Springback
0.0

0.0 20.0
R/t
Comparison of Sidewall Curl(1.60mm)
10.0
x 0.001

EDDS
HS440
HSLA350
Curvature of Sidewall Curl

DP600
DP980

Sidewall Curvature
0.0 20.0
-5.0

R/t

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• Results of Springback Characterizations

(Within testing range of tooling radius: 1~23mm)
• Springback angle
– Increased almost linearly with R/t (concurred with Gardiner’s
results)
– Greater rate for higher strength steel
– Convergence at small R/t
• Sidewall curl
– Increased rapidly for different steels
– Reached the maximum at R/t=3~5
(in regular working range)
– Decreased with similar slopes for different steels
– Convergence at small R/t

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Rd Reff •Rd – tooling radius

Sidewall Curvature (1/r)

Pad
Die •Reff – effective part radius

Reff/t

Clamp Sample
R/t
Punch
Draw Die Process
• Control of sidewall curl in draw die processes
– Use minimum permissible die radii (Rd & Rp)
– Use maximum allowable blank holder force
– For Rd/t < 3: use minimum tool gap to reduce sidewall curl
– For Rd/t > 3: use maximum allowable tool gap to reduce sidewall curl
– The effective radius on part (Reff) remains constant
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• Primary Concerns:
– Springback & Curl, Wrinkling
• Springback Control Strategy:
– Use of small tool radii with “post
stretch” provided by stake beads
• Wrinkling Control Strategy:
– Application of upper pad and lower
binder

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Upper pad Binder

• Center upper pressure pad (3 ton force)

• Lower binder supported by the Nitrogen cylinders (72 ton
force) with a standoff of 0.005”

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Small radii Draw beads

• Small tool radii, R/t ~ 1

• Two draw beads enter the blank 15mm from the bottom of the
punch stroke to provide stretch needed for springback and curl
control

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6HF 6HF
6HF
6HF 6HF

Angles & gaps measured at 5 sections for both sides

6HF
Measuring Measuring
angle gap
µ

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Springback Angle of DP590 S-Rail

Mechanical properties 5.0
(2.0mm, Lubed)

Gauge 0.2 % YS UTS UE TE 4.0

Springback Angle (degree)

Steel Coating
(mm) (MPa) (MPa) (%) (%) 3.0

DP590 GA 2.07 400.1 642.0 14.0 20.9 5LJKW

5LJKW
2.0

Sec. 1 Sec. 5 1.0

0.0
/HIW
/HIW
-1.0

-2.0
0 1 2 3 4 5 6

Section

Maximum Gap of The Sidewall of DP590 S-Rail

• The springback angle is less (2.0mm, Lubed)
1.2

than 1.5o except sec. 5 (end) 1.0

Maximum Gap (mm)

where “post stretch” was not 0.8
/HIW
/HIW

presented 0.6

0.4

• The maximum gap due to 0.2

5LJKW
5LJKW

sidewall curl is about 1.0mm 0.0

0 1 2 3 4 5 6

Section

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Springback Angle of DP590 S-Rail

(2.0mm, Lubed)
5.0
75 ton binder force
4.0
Springback Angle (degree)

‡ Forming process is robust

32 ton binder force
3.0
5LJKW
5LJKW
2.0

enough to condone the 1.0

binder force variations 0.0

/HIW
/HIW
-1.0

‡ The largest increase in -2.0

0 1 2 3 4 5 6

Section
springback angle was about
Maximum Gap of The Sidewall of DP590 S-Rail
2 degrees on the left side 1.2
(2.0mm, Lubed)

‡ Lower binder force actually

75 ton binder force
1.0
32 ton binder force
Maximum Gap (mm)

improved the sidewall curl 0.8

0.6

slightly 0.4
/HIW
/HIW

5LJKW
5LJKW
0.2

0.0
0 1 2 3 4 5 6

Section

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Springback Angle of DP590 S-Rail

(2.0mm, 75 ton Binder Force)
5.0
Lubed
4.0

Springback Angle (degree)

As is
3.0
5LJKW
5LKW

‡ Forming process is
2.0

1.0

insensitive to the changes -1.0

0.0
/HIW
/HIW

of lubrication -2.0
0 1 2 3 4 5 6

‡ Springback angle variations

Section

Maximum Gap of The Sidewall of DP590 S-Rail

are about 1 degree 1.2

(2.0mm, 75ton Binder Force)

‡ Sidewall curl were slightly

Lubed
1.0
As is
5LJKW

Maximum Gap (mm)

0.8
improved 0.6
/HIW

0.4

0.2

0.0
0 1 2 3 4 5 6

Section

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Springback Angle of DP590 S-Rail

Mechanical properties 8.0
(2.0mm, Lubed, 75 ton Binder Force)

Gauge: 2.0 mm
Gauge 0.2 % YS UTS UE TE
Springback Angle (degree)

Steel Coating 6.0 Gauge: 1.80 mm

(mm) (MPa) (MPa) (%) (%) 5LJKW
5LKW
DP590 CR 1.85 405.6 675.7 14.2 21.9 4.0

DP590 GA 2.07 400.1 642.0 14.0 20.9

2.0

/HIW
/HIW
‡ The forming results are stable
0.0

-2.0
for thicknesses variation except 0 1 2 3

Section
4 5 6

at section 5 Maximum Gap of The Sidewall of DP590 S-Rail

‡ Increase in springback angle

(2.0mm, Lubed, 75ton Binder Force)
3.5
Gauge: 2.0 mm
(2~3 degrees) was found for 3.0
Gauge: 1.80 mm 5LJKW
5LJKW
Maximum Gap (mm)

2.5
thinner material at section 5 2.0

‡ Increase in sidewall curl 1.5

1.0
(2.5mm) was also found for 0.5
/HIW
/HIW

thinner material at section 5 0.0

0 1 2 3 4 5 6

Section

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Mechanical properties Springback Angle of DP590 S-Rail

(2.0mm, Lubed, 75 ton Binder Force)
8.0

Gauge 0.2 % YS UTS UE TE Gauge: 2.0 mm

Steel Coating

Springback Angle (degree)

(mm) (MPa) (MPa) (%) (%) 6.0 Gauge: 1.80 mm
5LJKW
5LKW
DP590 CR 1.85 405.6 675.7 14.2 21.9
4.0
DP590 GA 2.07 400.1 642.0 14.0 20.9
2.0

‡ The forming results are stable 0.0

/HIW
/HIW

for thicknesses variation -2.0

0 1 2 3 4 5 6

Section
except at section 5
Maximum Gap of The Sidewall of DP590 S-Rail
‡ Increase in springback angle 3.5
(2.0mm, Lubed, 75ton Binder Force)

(2~3 degrees) was found for 3.0

Gauge: 2.0 mm
Gauge: 1.80 mm 5LJKW
5LJKW

Maximum Gap (mm)

thinner material at section 5 2.5

2.0

‡ Increase in sidewall curl 1.5

1.0

(2.5mm) was also found for 0.5

/HIW
/HIW

thinner material at section 5 0.0

0 1 2 3 4 5 6

Section

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Laser Guided Demo of

Temperature Temperature
Gauge Measurement

2
4 3 1

Locations of Temperature Measurements

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Comparisons of Temperature
240
(Binder Force = 75 ton)
HSLA350 (1.9mm, GI) - Mill Oil
HSLA350 (1.9mm, GI) - Lubed
DP590 (1.8mm, CR) - Mill Oil
200
DP590 (1.8mm, CR) - Lubed
DP590 (2.0mm, GA) - Mill Oil
DP590 (2.0mm, GA) - Lubed

Temperature ( F)
160

O
DP780 (1.9mm, CR) - Mill Oil
DP780 (1.9mm, CR) - Lubed
120

80

40

0
1 2 3 4
Locations of Temperature Measured

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• The temperature increase was caused by the friction of part with tooling
• The temperature varies with the material-tooling contact force and area, which
change with the steel strengths and gauges
• Part temperature decreased rapidly through heat dissipation
• Part temperature did not elevate the tooling temperature significantly
• Lubrication did not show much improvement on part temperature
• Coating could reduced the tooling contact force and part temperature

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Stamping Press /HIWEDFN 5LJKWEDFN

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/HIWIURQW 5LJKWIURQW

/HIW 5LJKW
EDFN EDFN Tonnage meter

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Locations of Stamping Force Measurements

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Comparisons of Press Tonnage Comparisons of Press Tonnage

(Binder Force = 72 ton) (Binder Force = 33 ton)
700 700
HSLA350 (1.9mm, GI) - as isl HSLA350 (1.9mm, GI) - as is
600 HSLA350 (1.9mm, GI) - lubed 600 HSLA350 (1.9mm, GI) - lubed
DP590 (1.8mm, CR) - as is DP590 (1.8mm, CR) - as is
500 DP590 (1.8mm, CR) - lubed 500 DP590 (1.8mm, CR) - lubed
Tonnage (ton)

DP590 (2.0mm, GA) - as is

Tonnage (ton)
DP590 (2.0mm, GA) - as is
400 DP590 (2.0mm, GA) - lubed 400 DP590 (2.0mm, GA) - lubed
DP780 (1.9mm, CR) - as is DP780 (1.9mm, CR) - as is
300 DP780 (1.9mm, CR) - lubed 300 DP780 (1.9mm, CR) - lubed

200 200

100 100

0 0
Back Front Back Front Total Back Front Back Front Total
Left Left Right Right Left Left Right Right
Locations of Tonnage Measured Locations of Tonnage Measured

‡ No significant changes of press tonnage were found for different steel

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• A guideline for springback control was established on the basis

of experiment results by Mittal Steel
• The forming process designed based on the general guideline is
robust and capable to deal with different material and process
variations
• The tooling temperature in stamping remained the same with
ambient temperature though the part temperature was higher
• The press tonnage change due to different material and process
variations was less than 40 ton (<6.3% of total tonnage)
• Design of the forming process is the key to success!

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Thank You!

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