1. Method of Manufacturing Ultra-High Strength Steel Sheet Parts
Presenter: Jinjin Ha, UNH
PIs: Yannis Korkolis and Brad Kinsey, UNH
Jyhwen Wang, TAMU
Yip-Wah Chung, Jian Cao, Northwestern

2. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Industrial Need and Relevance: For lightweighting purposes, the use of UHSS is desirable. However, limited ductility, excessive springback, and tool life concerns are problematic. Thus, methods to form UHSS that address all of these concerns are required. This should include modeling efforts as well for virtual predictions and validation purposes.
NSF I/UCRC Planning Meeting

3. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Project Objectives:
Implement forming process on a servo-press to allow flexibility with respect to the process, i.e., variable ram motion, binder force, etc. control;
Simulate and validate formability, material, lubrication, and temperature effects;
Assess the die material and coating effects; and
Enable the use of UHSS sheet for more structural stamping applications.
Servo-press at Postech
NSF I/UCRC Planning Meeting

4. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Approach/Methodologies:
Investigate punch and binder motions/force trajectories using a servo-press that can improve formability of UHSS.
Barlat et al., 2015, IJMF
NSF I/UCRC Planning Meeting

5. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Approach/Methodologies:
The proposed scaled test article(s) is a combination of a B-pillar and shotgun.
Perform numerical simulations for validation of the process including punch and binder trajectories.
Metal Forming Magazine, March 2016
NSF I/UCRC Planning Meeting

6. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Approach/Methodologies:
Results from past servo-press research
Osakada et al, CIRP review paper, 2011
NSF I/UCRC Planning Meeting

7. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Deliverables:
Test component for further assessment
Servo-press trajectories for improved formability
Tooling life assessment and predictions
Numerical simulation models
Criteria and empirical guidelines
Barlat et al., 2016, MMTA
NSF I/UCRC Planning Meeting

8. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Budget and Timeline: Estimated cost of the project is $500k for two years.
Task / Milestone
Year 1
Year 2
Year 3 Q1 Q2 Q3 Q4
Tooling design/production
Implementation of process
Vary process parameters
 Material characterization
 Numerical model
NSF I/UCRC Planning Meeting

9. 1. Manufacturing Ultra-High Strength Steel Sheet Parts
Discussion:
Are the industrial need and relevance accurately captured?
Are the objectives realistic and complete?
Are the approaches technically sound and appropriate?
Are there alternative implementation paths or better approaches?
Are the deliverables impactful to industrial partners?
Are the budget and timeline reasonable?
Are there conflicts with intellectual property or trade secrets?
NSF I/UCRC Planning Meeting