Case studies on chain-die forming for AHSS

In this study, three case studies were conducted to develop a reliable finite element-based numerical model of Chain-die Forming (CDF) with AHSS. These simulations demonstrated the effectiveness of this forming process while capturing the mechanical behaviours of AHSS. The numerical modelling and simulations serve as Computer Aided Engineering (CAE) tools which determined tool geometries and control unwanted spring back. An automotive martensitic steel DOCOL 1400M from SAAB was adopted for this research as a typical AHSS material, which has a yielding strength of 1,150 MPa and a tensile strength of 1400-1600 MPa. There were three case studies involved (a) Case Study - 1: Forming AHSS 60° section; (b) Case Study - 2: Forming AHSS 90° section; and (c) Case Study - 3: Forming top-hat section. All three cases were conducted to achieve desired profiles in minimum number of passes without defects. Validation and verification of the CDF process were further demonstrated based on these case studies. According to the numerical and experimental results obtained, Chain-die Forming (CDF) can be considered as an affordable, sustainable and environmental friendly manufacturing process