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02 Hard and Soft Zones in Hot Formed Parts Jan 15 2013
02 Hard and Soft Zones in Hot Formed Parts Jan 15 2013
02 Hard and Soft Zones in Hot Formed Parts Jan 15 2013
PROCESS GOALS
Y 1150 MPa
Passenger
Zone El 6%
Deformation
Zone Y 400 MPa
El 15%
Y 1150 MPa
(a) Front view (b) Side view El 6%
before crash after crash
500 22MnB5
Laser welded joint
H340LAD
100
310-330 HV
485-515 HV
PHYSICS OF MATERIAL
Critical
cooling rate
to produce
martensite
P(t)
time log
P(T)
420
temperature
Goal Reached
Above 30K/s
Rockwell-C
Source: PhD.
Thesis Alberto
Turetta
l
na austenitisation
0.015 x ter es
+E rbid
ca e
h as
-P
martensitic
0.01 transformation
+Initial,
undistorted grid
se
ha
0.005 - P
se
ha
-P
k k: Thermal conductivity
Thin
Material
Validation of
basic effects
with Sysweld –
2002
Temperature
field after 4s
quenching time
in the blue area
only
Typical cooling
rate for a hard
zone with 100%
martensite
Typical cooling
rate for a soft
zone, mostly
bainite
0.015
austenitisation
e
h as
-P
martensitic
0.01 transformation
se
Pha
0.005 -
e
h as
-P
310-330
HV
0
485-
515HV
200 400 600 800 1000 1200 temperature
-0.005
/Altan/ 2012
With a Gleeble, it is
possible to measure
mechanical properties as
a function of temperature,
strain and strain rate
It is very expensive and
for low carbon hardenable
steel nearly impossible to
measure mechanical
properties of austenite for
low temperatures
HOW TO MODEL
Level 1
Without implementation of transformation plasticity
For two materials, hot forming process conditions and thin material
An engineering solution is to reduce the yield strength as a function of temperature in the
temperature range of phase transformation
For thick material this would not be possible
Level 2
Implemented transformation plasticity
For two materials, hot forming process conditions and thin material
Known phase proportions from simulation or dilatation curves
No modification of yield strength
Level 3
Method for thick material implemented, with the need for additional and more difficult to
measure material properties
The secret of no distortion is to make sure that all phase transformations happen when
the part is still in the die. Then transformation plasticity cares for that there are only little
residual stresses when the part is taken out of the die
In case the part is taken too early out of the die and there are hot spots that show
retained austenite, the phase transformation will cause local stresses that lead to
distortion – also for a part planned to be fully hardened. This is then a bad designed die
and has to be improved
It would be sufficient to modify material properties in the phase transformation range to a
low yield strength to simulate the transformation plasticity effect that has to happen in the
die. PS2G would show for hot spots that exist when the part is out of the die way too high
distortion today – residual stresses are not killed during phase transformation
Because the phase transformations have to happen in 10s, there will be only two cooling
curves in the dilatometer test for a partial hardened die. This can be modeled with two
materials, as discussed
A usual cooling rate for hardening is about 50K/s, to be on the safe side
To complete the software and to avoid the necessity to artificially modify material
properties transformation plasticity is needed – but not more. But the proposed trick
should work as well