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Journals / Politeknik Dergisi / 2026 / Cilt: 29 Sayı: 4

Evaluation of Surface and Dimensional Phenomena in Punching of DP800 Advanced Strength Steel Utilising The Cockcroft-Latham Damage Model

Cockcroft-Latham Hasar Modeli Kullanılarak DP800 İleri Mukavemetli Çelik Delme-Zımbalama İşleminde Yüzey ve Boyut Olayların Değerlendirilmesi

Bilge Demir(KARABUK UNIVERSITY)0000-0002-3617-9749
Samet Seras(KARABÜK ÜNİVERSİTESİ)0000-0001-9746-1580
Hakan Gürün(GAZİ ÜNİVERSİTESİ)0000-0001-6189-6830
Pages
1–9
Publication Date
2026-04-21
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

The findings deliver novel insights into tool-geometry optimisation and damage prediction, offering practical guidelines for improving manufacturing precision and process reliability in AHSS forming operations.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:This study presents a quantitative and original investigation of the punching behaviour of DP800 advanced high-strength steel (AHSS), widely used in automotive components due to its high strength-to-weight ratio.
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Key Findings & Data:Experimental tests on 1.5 mm thick DP800 sheets revealed a maximum true stress of ~900 MPa, accompanied by uniform elongation behaviour.
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Conclusion & Impact:The findings deliver novel insights into tool-geometry optimisation and damage prediction, offering practical guidelines for improving manufacturing precision and process reliability in AHSS forming operations.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Dual-phase steels · punching · shear surface

Abstract

This study presents a quantitative and original investigation of the punching behaviour of DP800 advanced high-strength steel (AHSS), widely used in automotive components due to its high strength-to-weight ratio. Experimental tests on 1.5 mm thick DP800 sheets revealed a maximum true stress of ~900 MPa, accompanied by uniform elongation behaviour. Five distinct punch geometries were evaluated, among which the P16 punch produced the smoothest cutting surface and the lowest burr height (0.08 mm), while the flat punch yielded 0.11 mm. Finite element simulations performed using the Cockcroft–Latham (C–L) damage model confirmed a critical damage constant of C = 1.5, which agrees with the experimental results. The shear zone accounted for approximately 28% of the total sheet thickness, and dimensional accuracy measurements indicated that the P16 punch achieved hole diameters closest to the nominal 20 mm. Unlike previous studies that primarily focused on the general behaviour of AHSS, this work provides a detailed quantitative analysis of DP800 punching mechanics and surface quality. The findings deliver novel insights into tool-geometry optimisation and damage prediction, offering practical guidelines for improving manufacturing precision and process reliability in AHSS forming operations.

Özet

Bu çalışma, yüksek mukavemet-ağırlık oranı nedeniyle otomotiv bileşenlerinde yaygın olarak kullanılan DP800 gelişmiş yüksek dayanımlı çeliğin (AHSS) delme davranışının nicel ve orijinal bir araştırmasını sunmaktadır. 1,5 mm kalınlığındaki DP800 saclar üzerinde yapılan deneysel testler, düzgün uzama davranışıyla birlikte ~900 MPa'lık maksimum gerçek gerilmeyi ortaya koymuştur. Beş farklı delme geometrisi değerlendirilmiştir; bunlar arasında P16 delme en pürüzsüz kesme yüzeyini ve en düşük çapak yüksekliğini (0,08 mm) üretirken, düz delme 0,11 mm vermiştir. Cockcroft-Latham (C-L) hasar modeli kullanılarak gerçekleştirilen sonlu elemanlar simülasyonları, deneysel sonuçlarla uyumlu olan C = 1,5'lik bir kritik hasar sabitini doğrulamıştır. Kesme bölgesi toplam sac kalınlığının yaklaşık %28'ini oluşturmaktadır ve boyutsal doğruluk ölçümleri, P16 delmenin nominal 20 mm'ye en yakın delik çaplarına ulaştığını göstermiştir. AHSS'nin genel davranışına odaklanan önceki çalışmalardan farklı olarak, bu çalışma DP800 delme mekaniği ve yüzey kalitesinin ayrıntılı bir nicel analizini sunmaktadır. Bulgular, takım geometrisi optimizasyonu ve hasar tahmini konusunda yeni bilgiler sunarak, AHSS şekillendirme operasyonlarında üretim hassasiyetini ve süreç güvenilirliğini artırmak için pratik kılavuzlar sunmaktadır.

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Cite This Article

Demir, B., Seras, S., Gürün, H. (2026). Evaluation of Surface and Dimensional Phenomena in Punching of DP800 Advanced Strength Steel Utilising The Cockcroft-Latham Damage Model. Politeknik Dergisi, Cilt: 29 Sayı: 4, 1–9. https://doi.org/10.2339/politeknik.1770895

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