TY - JOUR

T1 - Improving Hole Expansion Ratio by Parameter Adjustment in Abrasive Water Jet Operations for DP800

AU - Behrens, Bernd Arno

AU - Diaz-Infante, David

AU - Altan, Taylan

AU - Yilkiran, Deniz

AU - Wölki, Kai

AU - Hübner, Sven

N1 - Funding information: The presented work is a result of the project “Acoustic emission analysis for online monitoring in sheet metal forming,” project number BE 1691/183-1, granted by the German Research Foundation (DFG). The authors are thankful for the financial support. Additionally, the authors would like to thank to the Institute of Forming Technology and Machines (IFUM), Leibniz Universität Hannover, for hosting a guest researcher and allowing him to conduct the experiments at their facilities during a scientific exchange as an international collaboration with the Center for Precision Forming at The Ohio State University.

PY - 2018/9/17

Y1 - 2018/9/17

N2 - The use of Abrasive Water Jet (AWJ) cutting technology can improve the edge stretchability in sheet metal forming. The advances in technology have allowed significant increases in working speeds and pressures, reducing the AWJ operation cost. The main objective of this work was to determine the effect of selected AWJ cutting parameters on the Hole Expansion Ratio (HER) for a DP800 (Dual-Phase) Advanced High-Strength Steel (AHSS) with s0 = 1.2 mm by using a fractional factorial design of experiments for the Hole Expansion Tests (HET). Additionally, the surface roughness and residual stresses were measured on the holes looking for a possible relation between them and the measured HER. A deep drawing quality steel DC06 with s0 = 1.0 mm was used for reference. The fracture occurrence was captured by high-speed cameras and by Acoustic Emissions (AE) in order to compare both methods. Results indicated that using, regardless of the material, a small standoff distance, high water pressure, and slow traverse speed and cutting the sample underwater will delay the fracture in a hole expansion operation. Furthermore, the AE have proven to be adequate to measure cracks when optical methods are not feasible. In conclusion, based on the impact of the aforementioned parameters, it is possible to select, appropriately, the AWJ operation parameters to achieve the edge stretchability required for each forming process.

AB - The use of Abrasive Water Jet (AWJ) cutting technology can improve the edge stretchability in sheet metal forming. The advances in technology have allowed significant increases in working speeds and pressures, reducing the AWJ operation cost. The main objective of this work was to determine the effect of selected AWJ cutting parameters on the Hole Expansion Ratio (HER) for a DP800 (Dual-Phase) Advanced High-Strength Steel (AHSS) with s0 = 1.2 mm by using a fractional factorial design of experiments for the Hole Expansion Tests (HET). Additionally, the surface roughness and residual stresses were measured on the holes looking for a possible relation between them and the measured HER. A deep drawing quality steel DC06 with s0 = 1.0 mm was used for reference. The fracture occurrence was captured by high-speed cameras and by Acoustic Emissions (AE) in order to compare both methods. Results indicated that using, regardless of the material, a small standoff distance, high water pressure, and slow traverse speed and cutting the sample underwater will delay the fracture in a hole expansion operation. Furthermore, the AE have proven to be adequate to measure cracks when optical methods are not feasible. In conclusion, based on the impact of the aforementioned parameters, it is possible to select, appropriately, the AWJ operation parameters to achieve the edge stretchability required for each forming process.

KW - Abrasive water jet

KW - Advanced high-strength steel

KW - Blanking

KW - Hole expansion test

KW - Metal forming

UR - http://www.scopus.com/inward/record.url?scp=85054573860&partnerID=8YFLogxK

U2 - 10.4271/05-11-03-0023

DO - 10.4271/05-11-03-0023

M3 - Article

AN - SCOPUS:85054573860

VL - 11

SP - 241

EP - 252

JO - SAE International Journal of Materials and Manufacturing

JF - SAE International Journal of Materials and Manufacturing

SN - 1946-3979

IS - 3

ER -