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

高级高强度钢（AHSS）汽车零部件的修边造成的严重模具磨损，极大地增加了生产成本。实际上，修剪边缘的损坏会降低冲压件剪切边缘的质量，在随后的操作中有可能分裂，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，然后预测汽车饰件模具的磨损演变。**在与加拿大福特公司的合作中，温莎大学将首先确定发生在饰边模具边缘的磨损类型。使用福特的半成品修边设备，将DP980钢线圈连续修边至大量循环，从而在特定的修边条件下生产出磨损的修边模具。将使用最先进的显微镜、光谱学和轮廓测量技术对磨损的边缘进行细致的分析，以了解磨损的微观机制以及它们如何随着重复的修剪周期而演变。温莎大学还将建造一台仪器化的实验室规模的修边压力机，具有现场观察能力，以研究模具镶件在修边测试期间微观结构特征的演变。最后，将开发能够模拟微观结构损伤积累的数值工具，并预测模具磨损和随之产生的饰边钝化。**本研究将培养3名研究生和1名博士后，对饰边模具边缘的磨损、粘附、微裂纹和切屑的微观机理进行评估、分析和理解。此外，该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板材材料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，而且还有助于降低与冲压AHSS零件相关的维护成本，从而有助于减少车辆重量和燃料消耗。************

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.************