Transactions of Materials and Heat Treatment

Title：Lightweight design on side sill beam of ultra-high strength steel by roll forming

Authors： Wu Haibo1 Hou Di2

Unit： 1.Department of Mechanical Engineering Maanshan Technical College 2.School of Automotive Engineering Hunan Electrical College of Technology

KeyWords： Ultra-high strength steel side sill beam roll forming equivalent thinning lightweight load-bearing characteristics

ClassificationCode：TG142.41；TG332+.4

year,vol(issue):pagenumber：2025,50(7):88-95

Abstract：

The lightweight design of sild sill beam for HC550/DP980D+Z ultra-high strength steel was carried out, and considering the energy absorption difference between elastic and plastic stages, the equivalent thinning formula of high strength steel was modified. Then, according to the properties of HC820/DP1180D+Z ultra-high strength steel, the thickness of material after thinning was obtained, and the optimized forming process of material was designed. Furthermore, the profile tolerance and thinning rate of the produced parts were tested and analyzed, and based on static three-point bending and dynamic drop-weight impact, the load-bearing and energy absorption characteristics of sild sill beam were compared to verify the feasibility of the lightweight scheme. The results show that the thickness of the sild sill beam produced with HC820/DP1180D+Z ultra-high strength steel is reduced to 1.3 mm, which reduces the weight by about 15.38%. Twenty-six passes are required for roll forming, and both the strength and the maximum strain meet the production requirements. The measured profile tolerances of all points for the part are qualified, and the maximum thinning rate is 11.43%. The peak load of the static three-point bending is 14.2 kN, the peak load of the dynamic drop-weight impact is 16.0 kN, and the average load is 7.2 kN, which are all better than the original design scheme. Thus, it is feasible to use the modified equivalent thinning formula to carry out the lightweight design.

Funds：

安徽省高等学校科学研究重点项目（2023AH052789）；湖南省教育厅科学研究课题（23C0540）

作者简介：吴海波（1989-），男，硕士，讲师 E-mail：wuhaibo@mastc.edu.cn

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