Summary Residual stress dssess ment by means of the hole drilling techniqae is still regarded by many analysts as a phenomenon whose use is restricted to isotropic and homogeneous materials. The work caFried out in this paper tends to address this 'lack of certainty' through introdacing a verilication approach of experimentally assess ed residual stress values, The components investigated were produced under pure bending conditions and anulysed for their residual stress behaviour using a customized strain gaage rosette. This rosette was employed in order to detect the average and peak maximam strain relaxstion os a result of producing a hole by the high speed drilling technique. It is envisaged that the concept of the verffication method could lead to a better understanding with regard to residual stress analysis.

Orientador: Marcelo dos Santos Pereira / Banca: Marcelino Pereira Nascimento / Banca: Rosinei Batista Ribeiro / Resumo: Este projeto é um estudo do efeito springback em quatro tipos de aços de alta resistência, sendo estes bifásico, baixo carbono, endurecível após pintura e com interstícios livres, aplicados atualmente como matéria-prima na produção de veículos. Neste contexto está inserido o desenvolvimento de novos aços avançados de alta resistência em consonância com o projeto ULSAB-AVC, que visa à produção de veículos seguros e econômicos para o século 21. A caracterização mecânica do efeito springback foi realizada por intermédio de ensaio de conformação mecânica, denominado dobramento de três pontos ao ar, como uma adaptação ao ensaio de flexão cilíndrica livre. Foram avaliadas também as propriedades mecânicas do material definidas pelo ensaio de tração, objetivando a determinação da resistência à tração, do limite de escoamento e do alongamento. Além disso, foi avaliada a caracterização microestrutural dos aços avançados, identificando e quantificando-se as fases presentes em coexistência por meio do processamento digital de imagens. Os resultados mostram que o efeito springback no aço bifásico, devido à sua alta resistência mecânica, apresenta as maiores taxas de springback e causa uma diminuição na "razão de aspecto" dos grãos que sofreram conformação mecânica e tentaram retornar às suas formas originais. Aços de baixo carbono e endurecíveis após a pintura, não sofrem efeito springback suficiente para causar alteração na forma dos grãos, sendo que a variação da "razão de aspecto" depende da combinação do alongamento e resistência mecânica destes aços. Já o aço com interstícios livres, devido a sua menor resistência mecânica, o efeito springback apresenta as menores taxas e a variação da razão de aspecto depende somente da capacidade de alongamento desse aço / Abstract: This is a study of the springback effect on four kinds of high strength steel, wich are dual-phase, low carbon, bake hardening and interstitial free, currently used as feedstock in the production of vehicles. In this context is inserted the development of new advanced high steel resistance in accordance with the project ULSAB-AVC, which aims to produce safe and economical vehicle for the 21st century. The mechanical characterization of the springback effect was performed by means of a test of mechanical conformation, called three-point air bending, done by adapting to unconstrained cylindrical bending test. Were also evaluated the mechanical properties of material defined by the tensile test, in order to determine the tensile strength, yield strength and the elongation. Furthermore, was performed the microstructural characterization of advanced steels by identificating and quantificating of present phases in coexistence by means digital image processing. The results indicates that the springback effect in dual-phase steel, due to its high mechanical strength, has the highest springback rates and causes a decrease in the "aspect ratio" of the grains that suffered mechanical conformation attempting to return to its original forms. Low carbon and bake hardening steels, have not enough springback effect to cause change in the shape of the grains and the change of the "ratio aspect" depends on the combination of both elongation and mechanical strength of these steels. Yet on the interstitial free steel, due to its lower mechanical strength, the springback effect has the lowest rates and the change in "aspect ratio" depends only on elongation capacity of the steel / Mestre

Made available in DSpace on 2014-06-11T19:27:11Z (GMT). No. of bitstreams: 0 Previous issue date: 2012-03-05Bitstream added on 2014-06-13T20:16:10Z : No. of bitstreams: 1 silva_ea_me_guara.pdf: 1498613 bytes, checksum: 06fa171181e5ced1500ca8c7e2468fc9 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Este projeto é um estudo do efeito springback em quatro tipos de aços de alta resistência, sendo estes bifásico, baixo carbono, endurecível após pintura e com interstícios livres, aplicados atualmente como matéria-prima na produção de veículos. Neste contexto está inserido o desenvolvimento de novos aços avançados de alta resistência em consonância com o projeto ULSAB-AVC, que visa à produção de veículos seguros e econômicos para o século 21. A caracterização mecânica do efeito springback foi realizada por intermédio de ensaio de conformação mecânica, denominado dobramento de três pontos ao ar, como uma adaptação ao ensaio de flexão cilíndrica livre. Foram avaliadas também as propriedades mecânicas do material definidas pelo ensaio de tração, objetivando a determinação da resistência à tração, do limite de escoamento e do alongamento. Além disso, foi avaliada a caracterização microestrutural dos aços avançados, identificando e quantificando-se as fases presentes em coexistência por meio do processamento digital de imagens. Os resultados mostram que o efeito springback no aço bifásico, devido à sua alta resistência mecânica, apresenta as maiores taxas de springback e causa uma diminuição na “razão de aspecto” dos grãos que sofreram conformação mecânica e tentaram retornar às suas formas originais. Aços de baixo carbono e endurecíveis após a pintura, não sofrem efeito springback suficiente para causar alteração na forma dos grãos, sendo que a variação da “razão de aspecto” depende da combinação do alongamento e resistência mecânica destes aços. Já o aço com interstícios livres, devido a sua menor resistência mecânica, o efeito springback apresenta as menores taxas e a variação da razão de aspecto depende somente da capacidade de alongamento desse aço / This is a study of the springback effect on four kinds of high strength steel, wich are dual-phase, low carbon, bake hardening and interstitial free, currently used as feedstock in the production of vehicles. In this context is inserted the development of new advanced high steel resistance in accordance with the project ULSAB-AVC, which aims to produce safe and economical vehicle for the 21st century. The mechanical characterization of the springback effect was performed by means of a test of mechanical conformation, called three-point air bending, done by adapting to unconstrained cylindrical bending test. Were also evaluated the mechanical properties of material defined by the tensile test, in order to determine the tensile strength, yield strength and the elongation. Furthermore, was performed the microstructural characterization of advanced steels by identificating and quantificating of present phases in coexistence by means digital image processing. The results indicates that the springback effect in dual-phase steel, due to its high mechanical strength, has the highest springback rates and causes a decrease in the “aspect ratio” of the grains that suffered mechanical conformation attempting to return to its original forms. Low carbon and bake hardening steels, have not enough springback effect to cause change in the shape of the grains and the change of the “ratio aspect” depends on the combination of both elongation and mechanical strength of these steels. Yet on the interstitial free steel, due to its lower mechanical strength, the springback effect has the lowest rates and the change in “aspect ratio” depends only on elongation capacity of the steel

The thesis focuses on the manufacture of car body panels at Austin Rover and in particular the phenomenon of spring-back. After pressing of a shallow drawn panel its shape is often flatter than required. This loss of shape control corresponds to areas of small strains. The aim of the thesis is to describe the generation of a database of small strain information at discrete points on a drawn panel, which could be used in the numerical modelling of the drawing process.

The bending and spring back behaviors of DP780 and DP980 were investigated using experiments, analytical models, and PEA. An PEA study using 3D shells was first performed of the work by Queener and DeAngelis (1968) and demonstrated that the 3D shell element behavior in bending and springback, is similar to that from simple bending theory. Experimental and FE studies were then performed using DP780 and DP980 steels under simple and general bending conditions. Simple bending conditions were studied in V -die bending. General bending was studied for DP780 using a commercial bending machine. The PEA examined the effect of element formulation and material hardening assumptions on springback, bending stresses, and the residual stress distributions after springback. Corresponding simple and general bending analytical models were also compared. The simple bending model was from Queener and DeAngelis ( 1968), and the general bending model was from Tan et al. ( 1995), modified for Ludwig hardening. Overall, the PEA predicted the springback magnitude in the order; 2D continuum >3D continuum> 3D shells, and kinematic hardening> mixed hardening> isotropic hardening. In the V -die bending study the 3D shell PEA, using a calibrated mixed hardening assumption, produced the most accurate results. The PEA using pure isotropic hardening demonstrated that bending and springback behaviors for both steels were consistent with that described by simple bending theory. The behaviors demonstrated by the FEA using mixed or pure kinematic hardening were not. In the general bending study, the 3D continuum element FEA using pure kinematic hardening was the most accurate. The 3D continuum element FEA captured the bending stress interaction with the hardening assumption as well as thinning deformation, in agreement with the analytical model and thinning measured experimentally. 3D Shell elements could not capture these behaviors and significantly under-predicted springback under the pure isotropic hardening assumption. / Thesis / Master of Applied Science (MASc)

Strain path changes are common in complex automotive stampings, where sheet materials undergo a combination of drawing, stretching, and bending to achieve a desired part shape. Aluminum sheet alloys are increasingly used in vehicle structure light-weighting efforts, but limited formability and high levels of springback present challenges to the manufacturing and assembly processes. The current work explores springback levels in AA6016-T4 sheet after various pure bending operations, where sheets were first pre-strained in uniaxial, plane-strain, and biaxial tension. Finite element modeling of the pre-straining and subsequent bending operations will be performed using both isotropic and elasto-plastic self-consistent (EPSC) crystal plasticity approaches. Because the EPSC model incorporates backstresses informed by GND content, as measured via high-resolution EBSD, the predictions are more accurate than those of the isotropic model. The benefits and limitations of the current EPSC model, regarding accuracy of the predictions for the proposed strain path changes, are discussed.

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