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New Methodologies for Fracture Detection of Automotive Steels in Tight Radius Bending: Application to the VDA 238–100 V-Bend Test

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Abstract

Background

The VDA 238–100 tight radius V-bend test can be used to efficiently characterize the bendability and fracture limits of sheet metals in severe plane strain bending. Material performance in plane strain bending is critical for the selection of advanced high strength steels for energy absorbing structural components.

Objective

The detection of failure based upon a reduction in the punch force can lead to erroneous predictions of failure for ductile or thin gage alloys in the VDA 238–100 test. New failure criteria were proposed and evaluated across a range of automotive steels.

Methods

Four detection methods in the V-bend test were evaluated based upon the load drop, bending moment, novel stress metric and the strain rate for seven steels with strength levels from 270 to 1500 MPa. The appropriate failure threshold was identified from visual inspection of the surface during bending.

Results

The vertical punch force will decrease as a consequence of the mechanics in the V-bend test at intermediate bend angles even without fracture. The novel stress-based metric accounts for sheet thinning and could successfully identify “false positives” and punch lift-off when considering the strain-rate evolution.

Conclusions

Failure detection using the VDA load threshold method may significantly under-report the bend performance of alloys with intermediate-to-high bendability or thin gauges. The proposed stress-based metric can reliably detect fracture for bend angles in excess of 160° and be readily calculated using the existing data. The VDA load threshold for failure can work well for materials that exhibit significant cracking.

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Authors and Affiliations

  1. Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, Canada

    J. Noder & C. Butcher

  2. Honda R&D Americas Inc, 21001 State Route 739, Raymond, OH, 43067-9705, USA

    J. Dykeman

Authors
  1. J. Noder
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  2. J. Dykeman
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  3. C. Butcher
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Corresponding author

Correspondence to J. Noder.

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Funding and Acknowledgements

Financial support for this study was provided in part by the Natural Sciences and Engineering Research Council of Canada, the American Iron and Steel Institute (AISI), and Honda Research Americas (HRA). The authors would particularly like to thank Dr. Hesham Ezzat of AISI and Dr. Kishore Pydimarry of HRA for their support of the project. We would also like to gratefully acknowledge Kenneth Cheong from the University of Waterloo for his valuable discussion on V-bend experiments and Pedram Samadian for quenching of the PHS1500 sheets. The authors would like to thank Amir Zhumagulov for characterizing the 270 Mild steel constitutive response. The excellent work by Dr. Larour from voestalpine Stahl GmbH was particularly valuable for thinning evaluation in the tight-radius bend test.

Conflict of Interest

The authors declare that they have no conflict of interest.

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Noder, J., Dykeman, J. & Butcher, C. New Methodologies for Fracture Detection of Automotive Steels in Tight Radius Bending: Application to the VDA 238–100 V-Bend Test. Exp Mech 61, 367–394 (2021). https://doi.org/10.1007/s11340-020-00627-z

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