Predictive of die wear during trimming of high strength steel automotive parts

对高级高强度钢（AHSS）汽车零件进行修边会导致严重的模具磨损，从而显著增加生产成本。实际上，修剪边缘的损坏使冲压部件的剪切边缘的质量劣化，具有在后续操作中分裂的可能性，并且需要更频繁的模具维护。本研究的主要目的是开发一种方法来确定磨损的微观机制，然后预测磨损的演变在汽车装饰模具。温莎大学与加拿大的福特公司合作，将首先确定发生在切边模边缘的磨损类型。使用福特的半生产修边设备，DP 980钢卷将被连续修边到大量的周期，以便在特定的修边条件下生产磨损的修边模具。将使用最先进的显微镜、光谱学和轮廓测量技术对磨损的修边模具边缘进行细致分析，以了解磨损的微观机制以及它们如何随着重复的修边循环而演变。一个仪器化的实验室规模的修边机也将在温莎大学建造，具有现场观察能力，以调查在修边测试过程中模具插入物的微观结构特征的演变。最后，将开发数字工具，能够模拟微观结构损伤的积累和预测模具磨损和随之而来的修边钝化。在本研究中，3名研究生和1名博士后将接受培训，以评估，分析和理解的磨损，粘附，微裂纹和切边模具边缘附近的崩落的微观机制。此外，博士生将开发预测工具，使福特工艺工程师能够评估模具材料/涂层和AHSS板材的各种组合的耐久性。这不仅有助于选择更耐用的工具材料/涂层，还有助于降低与冲压AHSS零件相关的维护成本，从而有助于降低车辆重量和燃油消耗。

The severe die wear that results from trimming advanced high-strength steel (AHSS) automotive parts is significantly increasing production costs. Indeed, damage of the trim edges deteriorates the quality of the sheared edges of stamped parts with potential for splitting in subsequent operations, and requires more frequent die maintenance. The broad objective of this research is to develop a methodology to determine the micro-mechanisms of wear, and then predict the evolution of wear in automotive trim dies. In collaboration with Ford of Canada, the University of Windsor will first determine the type of wear that occurs at the edges of trim dies. Using Ford's semi-production trimming facility, coils of DP980 steel will be continuously trimmed up to large numbers of cycles so as to produce worn trim dies under specific trimming conditions. The edge of worn trim dies will be meticulously analyzed using state-of-the-art microscopy, spectroscopy and profilometry techniques in order to understand the wear micro-mechanisms and how they evolve with repeated trimming cycles. An instrumented laboratory-scale trimming press will also be constructed at the University of Windsor with in-situ observation capability to investigate the evolution of microstructural features of die inserts during trimming tests. Finally, numerical tools will be developed that are able to model the accumulation of microstructural damage and predict die wear and the consequent dulling of the trim edges. In this research, 3 graduate students and 1 post-doctoral fellow will be trained to evaluate, analyze and understand the micro-mechanisms of wear, adhesion, micro-cracking and chipping near the edge of trim dies. Furthermore, the PhD student will develop predictive tools that will enable Ford process engineers to evaluate the durability of various combinations of die materials/coatings and AHSS sheet materials. This will not only facilitate the selection of more durable tool materials/coatings, but it will also help to reduce maintenance costs associated with stamping AHSS parts, which help to reduce vehicle weight and fuel consumption.