Modelling of forming and quenching of ultra high strength steel components for vehicle structures

Sammanfattning: The doctoral thesis deals with modelling and simulations in integrated product and process development. The research concerns with development of models and methods for simulation of component manufacturing and product functionality. One aim of the research project is to enable the introduction of tubular high strength components in vehicle structures. The new type of structure components requires changes in the product development process in order to closely couple the design with the development of the manufacturing tools and process parameters. The coupling is performed with the development and introduction of new modelling and simulation methods and tools for the analysis of thermomechanical forming of tubular high strength components. In this work the requirements for the numerical models are studied and evaluated by comparisons with experimental results. A set of tests are defined, performed and evaluated for establishing the required material parameters for the analysis of the manufacturing process. An inverse modelling method has been developed for evaluation of continuous cooling and deformation experiments performed in Gleeble 1500 thermomechanical simulator equipment. Spray cooling experiments have been designed for the modelling of the cooling effects of different types of spray nozzles. A model and an algorithm for the introduction of water spray cooling from a set of water spray nozzles has been developed and implemented in to a thermomechanical analysis code. A tool and a set of experiments are used for the verification of thermomechanical analyses of the component forming and quenching process.