Stripping failure of punching pin in GPa-grade steels

GPa-grade steels which possess the ultimate tensile strength over 1000 MPa and higher elongation have been thoroughly researched to replace conventional high-strength steels in automobile industry to enhance fuel efficiency without sacrificing crashworthiness. However, high strength of GPa-grade steel does not only induce punching pin buckling due to high contact pressure, but also abrasive wear on the mold surface due to the unstable contact that results from the large amount of springback, which tend to impede widespread usage of GPa-grade steels. In this research, design criteria for an optimal aspect ratio of the punching pin preventing buckling failure has been proposed by linking with experimental and numerical analyses, which is validated with the analytic solutions. Furthermore, in order to prevent stripping failure, it is highly recommended that one of the main factors, a blank holder force (BHF), over 1.5 MPa has to be maintained during the withdrawal process to minimize the effect of springback in stamped panels applying GPa-grade steel, which is able to extend the tool life of the side punching pin about 100,000 cycles.