Abstract
Aiming at the need for lightweight requirements of the components in the bus, combined with the advantages of the hot stamping ultra-high-strength steel, a new television (TV) bracket was proposed. The finite element (FE) simulation of the beam part in the TV bracket during the indirect hot stamping process was discussed. After two-stages of pre-forming, the blank was in good formability and without visible cracks. According to the FE simulation results, the punch speed, quenching force, and quenching time significantly affected the temperature, microstructure, hardness, and mechanical properties of the beam part during hot stamping. With the increase of the quenching force and quenching time, the martensite fraction of the beam part was increased. For the beam part, the punch speed should be at least 80 mm/s during the forming stage. For complete quenching, the quenching force should be above 1000 kN and quenching time should be up to 10 s. Based on the parameters from the FE simulation, the forming experiment of the beam part was discussed. Microstructure analyses and microhardness tests as well as tensile tests of the hot stamping beam part were performed. The results confirmed that the FE simulation of the beam part was reliable.
Highlights
Lightweight has become an inevitable trend under energy and sustainable development in the bus.Lightweight requires making the components lighter and, at the same time, stronger
Because the stress level and the hardening of the ultra-high-strength steel (UHSS) decrease at higher temperatures, hot stamping allows UHSS forming of complex parts for which the production with conventional methods is either impossible or extremely difficult
Since hot stamping allows forming the complex parts, multi-component assemblies can be redesigned and formed as one component, eliminating some downstream joining processes such as welding or joining. It can be divided into direct hot stamping and indirect hot stamping
Summary
Lightweight has become an inevitable trend under energy and sustainable development in the bus. Combined with the hot stamping process, this kind of material allows manufacturing parts with ultra-high strength, minimum springback, and reduced sheet thickness [7,8]. Since hot stamping allows forming the complex parts, multi-component assemblies can be redesigned and formed as one component, eliminating some downstream joining processes such as welding or joining. It can be divided into direct hot stamping and indirect hot stamping. Indirect hot stamping was developed to reduce wear on the tools when dealing with uncoated and to form complex when dealing with uncoated steel and to form more complexsteel shape features [9].
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