Approaches for springback reduction when forming ultra high-strength sheet metals

Nowadays, the automotive industry is challenged constantly by increasing environmental regulations and the continuous enhancement of standards with regard to passenger's safety (NCAP, Part 1). In order to fulfil the aforementioned requirements, the use of ultra high-strength steels in research and industrial applications is of high interest. When forming such materials, the main problem results from the large amount of springback which occurs after the release of the part. This paper shows the applicability of several approaches for the reduction of springback amount by forming of one hat channel shaped component. A novel approach for springack reduction which is based on forming with an alternating blank draw-in is presented as well. In this investigation an ultra high-strength steel of the grade DP 980 was used. The part's measurements were taken at significant cross-sections in order to provide a qualitative comparison between the reference geometry and the part's released shape. The obtained results were analysed and used in order to quantify the success of particular approaches for springback reduction. When taking a curved hat channel shaped component as an example, the results achieved in the investigations showed that it is possible to reduce part shape deviations significantly when using DP 980 as workpiece material. (paper)