OPTIMAL PRODUCTION TRIMMING PROCESS FOR AHSS

EDGE STRETCHABILITY IMPROVEMENT

Hua-Chu (Michael) Shih
United States Steel Corporation

Gene Hsiung
General Motors Company

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Outline
Introduction
Edge Fracture
Flat Trim vs. Shear Trim

Cutting Test
Edge Stretchability
Trimmed Edge Tension Test
Half Specimen Dome Test

Trimmed Edge Characterization

Summary

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Introduction Edge Fracture

Edge Fracture
FLD failed to
predict
May be due to
poor trimmed
edge condition
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Introduction Flat Trim

Side View

Upper Blade

Holding Pad
Sheet Metal

Lower Blade

Die Clearance

Front View

Shear Rake Angle =0

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Introduction Flat Trim

Quality
Poor Trimmed Edge Stretchability

Cost

Split Parts
Tool Wear/Damage
Energy Consumption
Down Time

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Introduction Shear Trim

Back Cut Angle
(clearance angle)

Upper Blade

Holding Pad

Upper Blade Rake Angle Q2

Sheet Metal

Lower Blade Rake Angle Q1

Lower Blade

Die Clearance

Front View

Shear Rake Angle Q3

Shearing Parameters ( Q1,Q2,Q3)

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Introduction Shear Trim

Quality
Better Trimmed Edge Stretchability

Cost

Less Split Parts

Less Tool Wear/Damage
Reduce Energy Consumption
Reduce Down Time

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Test Materials

Thickness

Yield

Tensile

Total

Material

(mm)

Elong.
(%)
26.4
26.7
14.0
14.1

value

1.0
1.0
1.2
1.2

Strength
(MPa)
645
659
994
992

Value

DP600 - L
DP600 - T
DP980 - L
DP980 - T

Strength
(MPa)
391
411
677
660

0.16
0.15
0.14
0.14

0.86
1.03
0.73
1.05

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Cutting Conditions
Flat Trim

Shear Trim

0 degree

1 degree

Shear Trim

Shear Trim

2 degree

3 degree

Shear Trim OT

Optimized (6,6,3)

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Cutting Force
160
140

DP600
DP980

Flat Trim

Reduction Ratio (%)

Peak Load (kN)

120
100
80
60

Shear Trim

100%
80%
60%
40%

DP600
DP980

20%

40

0%

20

1
2
3
Shear Rake Angle (Degree)

0
0

Shear Rake Angle (Degree)

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Cutting Force Estimation

Flat Trim

F C1 T L UTS
Trim Blade

Material Constant
C1=0.77, DP600
C1=0.68, DP980

Sheet Metal

Shear Trim F Cshear T 2 UTS 2 tan

Material Constant
C Shear =1.00, DP600
C Shear = 0.86, DP980

L
T

Trim Blade

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Sheet Metal

Edge Stretchability
Trimmed Edge Tension Test
Milled Edge

As-Trimmed Edge

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Edge Stretchability Tension Test

DP600
Cutting Condition

Flat Trim-T
Flat Trim-L
Shear Trim 1-T
Shear Trim 1-L
Shear Trim 2-T
Shear Trim 2-L
Shear Trim 3-T

Shear Trim 3-L

Shear Trim OT-T
Shear Trim OT-L

16

18

20

22

24

Total Elongation %

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26

28

Edge Stretchability Tension Test

DP980

DP600
Flat Trim

Cutting Condition

Cutting Condition

Flat Trim
Shear Trim 1
Shear Trim 2
Shear Trim 3
Shear Trim OT
Milling

Shear Trim 1
Shear Trim 2
Shear Trim 3
Shear Trim OT
Milling

Laser

Laser

Water

Water

12

14

16

18

20

22

24

26

28

Total Elongation %

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10

12

14

Total Elongation %

16

Edge Stretchability
Half Specimen Dome Test

3D Stretching

Edge Fracture

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Edge Stretchability Dome Test

DP600

DP980
36

Longitudinal
Transverse

42
38
34
30
26
22

18

Strain at Failure (%)

Strain at Failure (%)

46

Longitudinal
Transverse

32
28
24
20
16
12
8
4
0

14
Water

Laser

Milling

Shear Shear Shear Shear

Trim OT Trim 3 Trim 2 Trim 1

Flat
Trim

Water

Laser

Cutting Condition

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Shear Shear
Trim OT Trim 3

Shear
Trim 2

Shear Flat Trim

Trim 1

Cutting Condition

Trimmed Edge Characterization

Macrographs of Cutting Edge

Smooth

Formation
Section

Flat Trim

Striations
Laser

Section

Shear Trim OT

Section

Section

Water Jet

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Trimmed Edge Characterization - Microhardness

300

320

Flat Trim-1
Flat Trim-2

280

300
280

260

SAZ

260

240

HV

HV

Laser-1
Laser-2

240

Fracture

220

220
200

Burnish

200

Burnish

180
0

Hardness 1

200

400

600

800

180

1000 1200 1400 1600

200

Distance from the Trimmed Edge (m)

Fracture

600

800

1000 1200 1400 1600

Distance from the Trimmed Edge (m)

280

260

Shear Trim OT-1

Shear Trim OT-2

Water-1
Water-2

240

260

220
240

HV

HV

Hardness 2

400

200

220

180
200

160
180
0

200

400

600

800

1000 1200 1400 1600

Distance from the Trimmed Edge (m)

140
0

200

400

600

800

1000 1200 1400 1600

Distance from the Trimmed Edge (m)

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Trimmed Edge Characterization - Microhardness

300

280

Flat Trim
Shear Trim 1 degree
Shear Trim OT
Laser
Water

SAZ

HV

260

240

220

200

180
0

200

400

600

800

1000

1200

1400

Distance from the Trimmed Edge (m)

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1600

The Improvement of the Mechanical Trimming

Process
Flat Trim
Shear Trim 1 -Dull

Conventional
Shear

Shear Trim 1 -Sharp

Shear Trim OT

Flat Trim-Polish
Laser
Water
0

10

20

30

Strain at Failure (%)

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40

50

Summary
The traditional trim condition with zero-degree angles has the lowest
trimmed edge stretchability, while water jet cutting has the highest.
The developed optimal mechanical trimming process (OT) can improve
the cutting condition more than 60% total elongation when compared to
the traditional trimming process.
The laser cutting and water jet cutting has better trimmed edge
stretchability than mechanical cutting. However, the water jet cutting
edge rusted more easily and should be avoided in production.
The post polishing process can be used as an alternative way to
improve the mechanical trimmed edge stretchability.
A shear trim with 15% die clearance is recommended in the production
trimming set up for AHSS.

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