Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping
Based on the principle of hot stamping, a simulation model of hot stamping was established. The blank contour line of U part was optimized by using a multiple iterative algorithm. By comparison with the simulation and experimental data, the multiple iterative optimization algorithm was verified. Mor...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2016
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| Cite this: | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping / Z.Q. Zhang, X.F. Jia, Y.J. Wang, P. Gao // Проблемы прочности. — 2016. — № 1. — С. 91-96. — Бібліогр.: 11 назв. — англ. |
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| author | Zhang, Z.Q. Jia, X.F. Wang, Y.J. Gao, P. |
| author_facet | Zhang, Z.Q. Jia, X.F. Wang, Y.J. Gao, P. |
| citation_txt | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping / Z.Q. Zhang, X.F. Jia, Y.J. Wang, P. Gao // Проблемы прочности. — 2016. — № 1. — С. 91-96. — Бібліогр.: 11 назв. — англ. |
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| description | Based on the principle of hot stamping, a simulation model of hot stamping was established. The blank contour line of U part was optimized by using a multiple iterative algorithm. By comparison with the simulation and experimental data, the multiple iterative optimization algorithm was verified. Moreover, the blank contour lines of a bumper and the B-pillar of Numisheet 2008 were optimized. The result showed that the multiple iterative method for optimizing initial blank contour line had high calculating speed and precision. The hot stamping parts’ contour lines match the ideal part contour lines quite well.
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UDC 539.4
Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength
Boron Steel in Hot Stamping
Z. Q. Zhang,
1
X. F. Jia, Y. J. Wang, and P. Gao
College of Materials Science and Engineering, Jilin University, Changchun, China
1 Zhangzq@jlu.edu.cn
Based on the principle of hot stamping, a simulation model of hot stamping was established. The
blank contour line of U part was optimized by using a multiple iterative algorithm. By comparison
with the simulation and experimental data, the multiple iterative optimization algorithm was verified.
Moreover, the blank contour lines of a bumper and the B-pillar of Numisheet 2008 were optimized.
The result showed that the multiple iterative method for optimizing initial blank contour line had high
calculating speed and precision. The hot stamping parts’ contour lines match the ideal part contour
lines quite well.
Keywords: high strength boron steel, hot stamping, optimization analysis, contour line,
finite element method.
Introduction. Hot stamping technology is the key to the lightweight of automobile
and has been increasingly used in manufacturing inside door beam, roof rail, bumper,
A/B/C-pillar reinforcements, etc. [1, 2]. Accurate design of initial blank contour line can
reduce the possibility of forming defects and improve the part quality [3, 4]. Scientists have
got many computing methods under different assumptions such as velocity field method
[5], slip line field method [6, 7], geometric mapping [8], potential field simulation [9, 10]
for cold stamping process. However, hot stamping process is a thermal-mechanical
coupling process. One step finite element inverse algorithm is mainly used in hot stamping
to get the initial blank contour line and redundant materials need to be removed by laser
cutting after hot stamping. It not only wastes raw materials but also results in low
production efficiency. Based on multiple iterative inverse algorithms, the process of hot
stamping was simulated and the optimized blank initial contour line was obtained by
establishing an optimized model, which required no further application of a cutting process
after hot stamping.
1. Process of Blank Initial Contour Optimization. In the process of optimization,
the border line of the part is the target object, where the border line of simulated part is
regarded as comparative object, while the blank initial contour line is the optimization
object. An optimal contour line is chosen from many calculating contour lines through
simulation. In simulation, one-step finite element inverse algorithm is employed to get
initial blank contour line and then parameters’ editor is initialized to mesh the whole model
and set parameters, input cycle definition and related control parameters, such as number of
cycle, object choice, coefficient of thermal expansion, etc. All those procedures can help to
establish an optimized model and offer the reference for the following iterative computation.
If an optimization meets the demands of presupposed forming precision, iteration will stop.
If not, further optimization will go on after establishing the new mesh within the maximum
iterations. The control process of the optimization model is shown in Fig. 1.
2. Contour Optimization and Forming Experiment of U-Shaped Part.
2.1. Contour Optimization of U-Shaped Part. The ideal U-shaped part has a length of
54 mm, width of 10 mm and height of 15 mm. One-step inverse algorithm is used to get the
blank initial contour line and then generate the blank with the thickness of 1 mm. The
position of the blank and die before forming is shown in Fig. 2. The initial blank mesh was
© Z. Q. ZHANG, X. F. JIA, Y. J. WANG, P. GAO, 2016
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 91
generated with 3131 nodes and 2592 elements by finite element meshing. The material
model should be a temperature and strain-rate dependent elastic-plastic model considering
phase transformation and thermal expand. Stress–strain curves of the material at various
temperatures are from Numisheet 2008 [11]. Figure 3 shows the contour line position of the
ideal part (target), formed part (compared), and the initial blank (object to modify). Preview
is the initial blank contour line obtained from multiple iterative inverse algorithms.
Figure 4 shows the size deviation distribution of the formed part before and after
optimization. Before optimization, contour line of formed part strongly deviated from that
of the ideal part. Within the tolerance 0.5 mm range, the contour line agreement of the
formed part and the ideal part was 88.22% and dimensional deviation at flange boundary
was the biggest, and the maximum was 0.84 mm. After the optimization, the contour line
agreement of the formed part and the ideal part reached 100%. Dimensional accuracy of the
part was greatly improved.
Z. Q. Zhang, X. F. Jia, Y. J. Wang, and P. Gao
92 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
Fig. 1. Schematic diagram of the control process for optimization model.
Fig. 2. Hot stamping of U-shape part.
Fig. 3. Contour lines of ideal part, formed part and initial blank.
2.2. Experiment on Forming U-Shaped Part. The material used in this study is
B1500HS, which is manufactured by Bao steel Group. Table 1 shows the composition of
this material.
The experiment uses DNS100 electronic universal testing machine and the heating
device is SX2-5-12 resistance furnace. B1500HS with a thickness of 1mm was cut along
the optimized contour line and placed into the furnace that had been heated to 930�C to
keep for 3 min. The heated blank was removed quickly from the furnace to the fixed die,
and then the punch descended very quickly to form the blank. The temperature of tools is
20�C and the stamping force is 6 kN.
The dimensions of the formed part, the optimized part and the ideal part are shown in
Table 2. Compared with the ideal part, the optimized part had a small contour line size
deviation that was within 0.5 mm and it is accepted by dimensional tolerance. Small flange
and low pressure occurred in the process might cause a little spring back. Figure 5 shows
the U-shaped part.
Optimization Analysis of Initial Sheet Metal Contour Line ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 93
a
Fig. 4. Contour line size deviation distribution histogram of formed part and ideal part before (a) and
after optimization (b).
T a b l e 1
Chemical Composition of B1500HS Steel (wt.%)
C Mn Cr Si Ti B
0.22 1.20 0.20 0.20 0.30 0.05
T a b l e 2
Comparison of the Optimized Contour and the Ideal Contour
Characteristic Tested part Simulated part Ideal part Error
Length (mm) 53.0 53.29 53.33 �0.33
Height (mm0 15.4 15.00 15.00 0.40
b
3. Test Verification.
3.1. Hot Stamping of Bumper and Optimization of the Blank Initial Contour Line.
Hot stamping process of a bumper was simulated and the blank used in the study has a
thickness of 1.5 mm and a friction coefficient of 0.35. The blank mesh had 13,441 nodes
and 35,095 elements. The blank initial contour line was obtained by finite element inverse
algorithm. Formed part did not meet the demands of dimensional precision and the
deviation mainly focused on the both ends of the long axis, which is shown in Fig. 6a. The
dimensional tolerance of the bumper is 0.5 mm. At the initial step of optimization, the
contour lines of formed part had a lower agreement that was 0.85%. The dimensional
deviation was largely from 0.5 mm to the maximum 16.31 mm, which did not meet the
demands of the dimensional precision. After four times optimized iterative computations,
the contour lines of formed part had an agreement that was 95.01%. The maximum
dimensional deviation was under 0.54 mm, which is shown in Fig. 6b. When the
presupposed dimensional precision was reached, iterative computation would stop, and the
optimized initial contour line of the bumper could be obtained.
94 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
Fig. 5. U-shaped part after stamping.
a
b
Fig. 6. Contour line size deviation distribution of formed and ideal part before (a) and after (b)
optimization.
Z. Q. Zhang, X. F. Jia, Y. J. Wang, and P. Gao
3.2. Hot Stamping of B-Pillar and Partial Optimization of the Blank Initial Contour
Line. Finite element simulation model of a B-pillar was established, and the material used
in the study is 22MnB5, which has a thickness of 1.95 mm. Because the material flow of
B-pillar in the forming process is rather complicated, optimization of the whole blank initial
contour line will not get an ideal result and thus partial optimization of the blank initial
contour line can be carried out and laser edge cutting can also be reduced greatly. The
B-pillar in the study didn’t match the size of the ideal part due to deep drawing in the
forming process. Three points A, B, and C were adopted along the contour line of the part
and this part of contour line was ignored (red color), shown in Fig. 7. Hot stamping
forming model of B-pillar was established, and the beam initial contour line was optimized.
Iterations were 8 and dimension tolerance was 0.7 mm.
Before the optimization, the contour line agreement of formed part and ideal part was
34.68%, and their maximum deviation was 2.79 mm. After six iterations, the agreement
reached 93.83%, and their maximum deviation was 1.14 mm (Fig. 8). The dimensional
accuracy of the formed part was strongly improved.
Conclusions. Based on the hot stamping principle, blank initial contour line of a
U-shape part was optimized by multiple iterative inverse algorithms. The results show that
the contour line agreement of formed part and ideal part has been greatly improved and the
hot stamping experimental data of U-shape part verify the effectiveness of this method. The
total optimization of bumper contour line and partial optimization of B-pillar contour line
also provided good results. Partial optimization covers the shortage of whole optimization
for complicated parts. Optimization of the blank initial contour line in hot stamping saves
raw materials and cutting time and provides a vital reference for industry production.
Acknowledgments. This work was supported by the National Natural Science
Foundation of China (Nos. 51205162 and 51275203).
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 95
Fig. 7. Schematic diagram of B pillar partial optimization.
Fig. 8. Contour line size deviation distribution histogram of formed part and ideal part.
Optimization Analysis of Initial Sheet Metal Contour Line ...
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Received 03. 08. 2015
96 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
Z. Q. Zhang, X. F. Jia, Y. J. Wang, and P. Gao
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| id | nasplib_isofts_kiev_ua-123456789-173421 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 0556-171X |
| language | English |
| last_indexed | 2025-12-07T17:32:08Z |
| publishDate | 2016 |
| publisher | Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| record_format | dspace |
| spelling | Zhang, Z.Q. Jia, X.F. Wang, Y.J. Gao, P. 2020-12-03T20:41:10Z 2020-12-03T20:41:10Z 2016 Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping / Z.Q. Zhang, X.F. Jia, Y.J. Wang, P. Gao // Проблемы прочности. — 2016. — № 1. — С. 91-96. — Бібліогр.: 11 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/173421 539.4 Based on the principle of hot stamping, a simulation model of hot stamping was established. The blank contour line of U part was optimized by using a multiple iterative algorithm. By comparison with the simulation and experimental data, the multiple iterative optimization algorithm was verified. Moreover, the blank contour lines of a bumper and the B-pillar of Numisheet 2008 were optimized. The result showed that the multiple iterative method for optimizing initial blank contour line had high calculating speed and precision. The hot stamping parts’ contour lines match the ideal part contour lines quite well. This work was supported by the National Natural Science Foundation of China (Nos. 51205162 and 51275203). en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping Анализ оптимизации начальной контурной линии листового металла для высокопрочной борсодержащей стали при горячей штамповке Article published earlier |
| spellingShingle | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping Zhang, Z.Q. Jia, X.F. Wang, Y.J. Gao, P. Научно-технический раздел |
| title | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping |
| title_alt | Анализ оптимизации начальной контурной линии листового металла для высокопрочной борсодержащей стали при горячей штамповке |
| title_full | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping |
| title_fullStr | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping |
| title_full_unstemmed | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping |
| title_short | Optimization Analysis of Initial Sheet Metal Contour Line for High-Strength Boron Steel in Hot Stamping |
| title_sort | optimization analysis of initial sheet metal contour line for high-strength boron steel in hot stamping |
| topic | Научно-технический раздел |
| topic_facet | Научно-технический раздел |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/173421 |
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