LAUSR

The combination of complex geometry and martensitic microstructure, characterized by ultrahigh strength and hardness, can be obtained in a single hot stamping process. However, this technology requires a multifaceted approach, allowing for an effective and efficient design process that will ensure the elements with the desired properties and shape are produced because of the high tool cost. This paper presents a comprehensive case study of the design process, simulation and experimental evaluation of the hot forming of an automotive door beam. The U-shaped beam designed with CAD was analyzed using the finite element method in the Autoform v.10 software. The modeling process included: a shape definition of the flat blank; a FEM analysis and design of the die, punches, and clamps; and a forming and quenching simulation. The results covered visualization of the forming and quenching stages for different variables including a forming limit diagram; a distribution of the drawpiece thinning; and a diagram showing the hardness of the drawpiece and its microstructure. Based on the results, a full-size tool for hot stamping was first modeled in the CAD and next manufactured. The tool was used to produce an initial sample series that was used to investigate the conditions for continuous use of the tool. One of the produced hot-stamped products was investigated for its hardness and microstructure, which exhibited a beneficial and fully martensitic microstructure with high hardness of above 400 HV1.