Abstract:
Dual-Phase (DP) steels, part of the Advanced High Strength Steels (AHSS) group, are preferred by car manufactures due to building demand for the body in white by using materials having excellent strength to weight ratio. During the automobile body producing a lot of metalworking process are used also very much punching-cutting also take place extensively. Important of this, all metalworking process must be optimized, understood very well to manage all well doing requirements. Sheet metal cutting operations such as blanking, fine blanking, trimming and punching aim to separate a certain amount of the material from the remaining sheet by using a controlled shearing and fracture at the contour of cut. There are many factors, which has huge effects on all properties of the worked materials during punching such as clearance, burr height, burr location, cut surface conditions, punch properties, materials properties and so. For doing well on manufacturing, understanding, and optimization of punching of dual phase steel are also very important with more other factors such as formability weld ability, wearing, cost, etc.
In this thesis, experimental and theoretical analysis using punches with different dies, for work materials under normal conditions are investigated by using automotive DP 600 sheet steel. Automotive DP600 sheet steel is one of the widely used steels in lots of industrial area particularly in automotive, has a big effect in, therefore selected for this study. This study comprised that punching operation by using different punch tips, failure analysis and, evaluation of punch shapes in terms of shearing and product quality, which subjected to punching. In the experiment, a simplified simulation model has been created using a digital-analog converter used to transmit the amplified signal to a computer. Punching experiments were carried out by using four different punched tips. In addition to that, simulations of the punching process by using deform software were also performed.
It is observed that experimental and simulations results have been good intersections to each other. This is showing the use of the simulation software on punching of dual phase steel, which can prove useful gain in time and cost saving. Punch shape results also give detailed information on the punching process and its effects.
