Surface and subsurface material modifications and graded material properties in sheet steel 1.0338 (DC04) and their influence on forming processes

For bulk material it is very well known, that the material properties differ between the material near the surface and the inner material (i.e. segregations). However, for sheet material a gradient of material properties in depth direction and its influence on forming processes was not yet investigated. Within experiments on sheet steel 1.0338 (DC04) a gradient in material properties was proven by hardness measurements for both unprocessed material as well as after conducting forming and milling processes. The characterisation shows a gradient in material hardness over the entire sheet thickness. The experimental results regarding forming processes, such as rolling and bending, additionally show an increase of the materials hardness due to work hardening. The problem from the inhomogeneous material properties leads to an inaccurate prediction of the forming behaviour of the workpiece in further processing. Machining experiments were conducted for transferring the knowledge of modified surface and subsurface layers onto forming processes and their simulation. The bending experiments and the corresponding process simulation of the spring back behaviour show, that the implementation of an inhomogeneous material property increases the prediction accuracy. Notably the prediction of the spring back behaviour of thinner sheet metals is highly improved. Therefore, an analysis of sheet metal properties in thickness direction and their consideration in forming process simulations is inevitable for the implementation of accurate material models.