Abstract
The longitudinal and transverse beams of trucks are manufactured with a large number of holes to fasten brackets for springs, fuel tanks, batteries etc. The quality of the holes, which is particularly influenced by the manufacturing process, has a major influence on the fatigue strength of the beams and thus the service lifetime of the vehicle. In most cases, the holes are produced using the highly economical shear cutting process. Previous investigations have shown that the fatigue strength of thin sheets can be increased by adjusting the shearing parameters and using a two-stage shear cutting process. This paper discusses the difference between one- and two-stage shear cutting on the hole quality of components made of S500MC (1.0984, thickness 8 mm) and its resulting fatigue strength. The hole quality is characterized by the geometry of the shear cut surface, its roughness, microstructure, and microhardness. It was shown that the two-stage shear cutting process allows producing holes of better quality than the ones manufactured by a one-stage shear cutting process. Furthermore, this resulted in an improved fatigue behavior.
Highlights
Heavy commercial vehicles play an important role in freight and passenger transport, which is reflected in the growing world market [1]
This paper discusses the difference between one- and two-stage shear cutting on the hole quality of components made of S500MC (1.0984, thickness 8 mm) and its resulting fatigue strength
This paper focuses on improving the shear cut surface quality in a one- and two-stage shear cutting process on thick steel sheet material to increase the fatigue strength of shear cut holes used for example in truck beams
Summary
Heavy commercial vehicles play an important role in freight and passenger transport, which is reflected in the growing world market [1]. Besides the quality of the product, trends such as fuel efficiency requirements and lightweight construction are the main drivers for the truck market [2]. When manufacturing longitudinal beams it is these requirements that come into play. In the material release process, the lifetime predictions of components made of steel sheet materials are based on material data determined by samples with polished edges. In series production, the highly economical shear cutting process is used [3], which means that the data obtained in the material qualification process cannot be transferred one-to-one to the components. High safety factors are used, and the component design is very conservative and contrary to the lightweight design concept
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
