Simulation Accuracy of Hot Form Quench (HFQ) Process

It could be said that HFQ® is a complex forming process, in which the strain rate and temperature change dynamically. Therefore, the accurate modelling of material behaviour during HFQ is crucial. Dr Mohamed Mohamed, Principal Technical Specialist, has developed a novel damage model to predict the failure limit during HFQ forming. The modern damage model must be fully calibrated and validated for accurate HFQ simulation. This calibration process requires a high-quality data set, including uniaxial tensile data and forming limit curve data at different temperature and strain rate regimes. ITL’s material testing and modelling facility includes DIC and running an optimisation code to calibrate the modern continuum damage mechanical model efficiently. The model validation must be relevant to the process parameters relevant to the HFQ production line. These parameters are i) forming process window (Forming speed, temperature, forming force and blank holder force, quenching time, and quenching force), (ii) Tool design, (iii) Temperature control and (iv) Lubrication. Harmonic integration and optimisation of all process parameters require good calibration and validation of the model.