Influence of shear cutting parameters on the fatigue behavior of a dual-phase steel

The influence of the edge condition of car body and chassis components made of steel sheet on fatigue behavior under dynamic loading presents a major challenge for automotive manufacturers and suppliers. The calculated lifetime is based on material data determined by the fatigue testing of specimens with polished edges. Prototype components are often manufactured by milling or laser cutting, whereby in practice, the series components are produced by shear cutting due to its cost-efficiency. Since the fatigue crack in such components usually starts from a shear cut edge, the calculated and experimental determined lifetime will vary due to the different conditions at the shear cut edges. Therefore, the material data determined with polished edges can result in a non-conservative component design. The aim of this study is to understand the relationship between the shear cutting process and the fatigue behavior of a dual-phase steel sheet. The geometry of the shear cut edge as well as the depth and degree of work hardening in the shear affected zone can be adjusted by using specific shear cutting parameters, such as die clearance and cutting edge radius. Stress-controlled fatigue tests of unnotched specimens were carried out to compare the fatigue behavior of different edge conditions. By evaluating the results of the fatigue experiments, influential shear cutting parameters on fatigue behavior were identified. It was possible to assess investigated shear cutting strategies regarding the fatigue behavior of a high-strength steel DP800. (paper)