Critical Factors and Improvement in Stamping Forming of Electro-galvanized High-strength Steel

CHEN Ming; DONG Bei; PENG Zhou; WEI Xing

doi:10.3969/j.issn.1674-6457.2026.03.011

PDF(3318 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (3) : 98-104. DOI: 10.3969/j.issn.1674-6457.2026.03.011

Iron and Steel Forming

Critical Factors and Improvement in Stamping Forming of Electro-galvanized High-strength Steel

CHEN Ming, DONG Bei, PENG Zhou, WEI Xing

Author information +

History +

Abstract

The work aims to investigate the frequent occurrence of drawing cracks during the stamping of electro-galvanized dual-phase steel HC340/590DPE+Z used in pillar reinforcement panels of a certain vehicle, so as to better promote the application of electro-galvanized high-strength steel in automotive body structural components. Mechanical properties (tensile strength and yield strength), microstructural characteristics, and friction coefficients of the material were analyzed with a Zwick Z050 tensile testing machine, an Olympus GX71 metallurgical microscope, and a LDA-30 lattice distortion analyzer. Additionally, multi-parameter stamping simulations were performed with the commercial software AutoForm R8 to identify the dominant factors affecting drawing cracks. Comprehensive analysis revealed that a high surface friction coefficient (critical threshold: >0.16) was the primary factor causing cracks during stamping. Material properties such as yield strength and work-hardening exponent (n-value) were secondary contributors. Optimizing electro-galvanizing process parameters reduces the friction coefficient from 0.213 to below 0.16, experimentally verifying that the cracking rate is maintained at 0%. This study provides theoretical insights and technical support for optimizing electro-galvanized high-strength steel processes and their stamping applications, enhancing the reliability of their use in automotive structural components.

Key words

electro-galvanized high-strength steel / stamping forming / friction coefficient / drawing crack / process optimization

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

CHEN Ming, DONG Bei, PENG Zhou, WEI Xing. Critical Factors and Improvement in Stamping Forming of Electro-galvanized High-strength Steel[J]. Journal of Netshape Forming Engineering. 2026, 18(3): 98-104 https://doi.org/10.3969/j.issn.1674-6457.2026.03.011

References

[1] 俞雁. 乘用车车门总成材料轻量化技术研究[D]. 广州: 华南理工大学, 2014.
YU Y.Research on Lightweight Technology of Passenger Car Door Assembly Materials[D]. Guangzhou: South China University of Technology, 2014.
[2] 袁志鹏, 牛超, 束祺成. QP和DP钢面内成形性能与边部成形性能对比研究[J]. 精密成形工程, 2024, 16(6): 115-121.
YUAN Z P, NIU C, SHU Q C.Forming Limit at Blank Edge and In-Plane Surface of QP and DP Steel[J]. Journal of Netshape Forming Engineering, 2024, 16(6): 115-121.
[3] 程国良. 汽车车身冲压模具开发同步工程的关键技术研究及应用[D]. 长沙: 湖南大学, 2008.
CHENG G L.The Key Technologies Researching and Application of Simultaneous Engineering in the Development of Automobile Body Stamping Dies[D]. Changsha: Hunan University, 2008.
[4] 罗仁平, 王燕, 赵金龙. 冲压同步工程在汽车产品设计开发中的应用[J]. 汽车技术, 2014(7): 5-7.
LUO R P, WANG Y, ZHAO J L.Application of Stamping Simultaneous Engineering in Auto Product Research and Development[J]. Automobile Technology, 2014(7): 5-7.
[5] 蒋浩民, 陈新平, 石磊, 等. 先进高强度钢板的冲压成形特性及其应用[J]. 塑性工程学报, 2009, 16(4): 183-186.
JIANG H M, CHEN X P, SHI L, et al.Forming Characteristics and Application of Advanced High Strength Steel[J]. Journal of Plasticity Engineering, 2009, 16(4): 183-186.
[6] 赵一鸣, 郑德兵, 柳一凡. 基于车身轻量化技术的高强钢应用趋势[J]. 汽车与配件, 2016(46): 76-79.
ZHAO Y M, ZHENG D B, LIU Y F.Application Trend of High Strength Steel Based on Lightweight Technology of Car Body[J]. Automobile & Parts, 2016(46): 76-79.
[7] 王春梅, 刘盼盼, 何鹏瞧. 电镀锌冲压钢板表面橘皮缺陷产生原因[J]. 理化检验-物理分册, 2023, 59(9): 36-38.
WANG C M, LIU P P, HE P Q.Cause of Orange Peel Defects on the Surface of Electrogalvanized Stamping Steel Plate[J]. Physical Testing and Chemical Analysis (Part A (Physical Testing)), 2023, 59(9): 36-38.
[8] SANTOS D, RAMINHOS H, COSTA M R, et al.Performance of Finish Coated Galvanized Steel Sheets for Automotive Bodies[J]. Progress in Organic Coatings, 2008, 62(3): 265-273.
[9] MANZENREITER T, ROSNER M, KURZ T, et al.Challenges and Advantages in Usage of Zinc-Coated, Press-Hardened Components with Tailored Properties[J]. BHM Berg-und Hüttenmännische Monatshefte, 2012, 157(3): 97-101.
[10] 国家市场监督管理总局, 国家标准化管理委员会. 金属材料拉伸试验第1部分: 室温试验方法: GB/T 228.1—2021[S]. 北京: 中国标准出版社, 2021.
State Administration for Market Regulation, Standardization Administration of the People’s Republic of China. Metallic Materials-Tensile Testing: Part 1: Method of Test at Room Temperature: GB/T 228.1—2021[S]. Beijing: Standards Press of China, 2021.
[11] 赵星宇, 王山生, 庞启航, 等. 碳元素配分行为对高强韧Q&P钢组织性能的影响[J]. 轧钢, 2023, 40(5): 12-17.
ZHAO X Y, WANG S S, PANG Q H, et al.Effect of Carbon Partition on the Microstructure and Properties of High Strength and Toughness Q & P Steel[J]. Steel Rolling, 2023, 40(5): 12-17.
[12] 何昌炜, 谢震, 章哲, 等. 800 MPa级DP钢冲压成形及裂纹扩展机理[J]. 塑性工程学报, 2013, 20(1): 121-125.
HE C W, XIE Z, ZHANG Z, et al.Study on Stamping Formability and Instability Mechanism of 800 MPa DP Steel[J]. Journal of Plasticity Engineering, 2013, 20(1): 121-125.
[13] GROCHE P, CHRISTIANY M.Evaluation of the Potential of Tool Materials for the Cold Forming of Advanced High Strength Steels[J]. Wear, 2013, 302(1/2): 1279-1285.
[14] 苏友煌, 王军辉, 冯怡爽, 等. 汽车内覆盖件无油冲压的数值模拟及工艺优化[J]. 塑性工程学报, 2019, 26(5): 42-50.
SU Y H, WANG J H, FENG Y S, et al.Numerical Simulation and Process Optimization of Dry Stamping for Automotive Interior Cover Parts[J]. Journal of Plasticity Engineering, 2019, 26(5): 42-50.
[15] 辛国升, 张永波. 基于AutoForm R7对顶盖后部外板成形性进行分析及回弹补偿研究[J]. 模具工业, 2020, 46(7): 34-39.
XIN G S, ZHANG Y B.Research on Formability Analysis and Springback Compensation of Outer Panel at the back of Head Cover Based on AutoForm R7[J]. Die & Mould Industry, 2020, 46(7): 34-39.
[16] 陈俊安. 汽车尾灯安装加强件拉延成形工艺参数优化[J]. 锻压技术, 2019, 44(11): 56-63.
CHEN J A.Optimization on Drawing Process Parameters of an Automobile Taillight Installation Reinforcement[J]. Forging & Stamping Technology, 2019, 44(11): 56-63.
[17] LANZON J M, CARDEW-HALL M J, HODGSON P D. Characterising Frictional Behaviour in Sheet Metal Forming[J]. Journal of Materials Processing Technology, 1998, 80: 251-256.
[18] ALVAREZ J, ORLOV I, ACHO L.An Invariance Principle for Discontinuous Dynamic Systems with Application to a Coulomb Friction Oscillator[J]. Journal of Dynamic Systems, Measurement, and Control, 2000, 122(4): 687-690.
[19] BENDAOUD N, MEHALA K, YOUCEFI A, et al.An Experimental and Numerical Investigation in Elastohydrodynamic Behaviour of a Plain Cylindrical Journal Bearing Heavily Loaded[J]. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 2012, 226(10): 809-818.
[20] 郭利, 汤瑞清. 滑动摩擦中能量耗散的研究[J]. 机械设计与制造工程, 2017, 46(3): 92-95.
GUO L, TANG R Q.The Study on Energy Dissipation in the Sliding Friction[J]. Machine Design and Manufacturing Engineering, 2017, 46(3): 92-95.
[21] KLARBRING A, CIAVARELLA M, BARBER J R.Shakedown in Elastic Contact Problems with Coulomb Friction[J]. International Journal of Solids and Structures, 2007, 44(25/26): 8355-8365.
[22] 温诗铸, 黄平. 摩擦学原理[M]. 北京: 清华大学出版社, 2012.
WEN S Z, HUANG P.Principles of Tribology[M]. Beijing: Tsinghua University Press, 2012.
[23] NUNOMURA Y, TAKASUGI T.Plastic Deformation and Fracture Behavior of Galvannealed Coating[J]. ISIJ International, 2003, 43(3): 454-460.
[24] TAKASUGI T, MACHIDA J.Plastic Deformation and Fracture behavior of Galvannealed Coating Under Compressive Stress Circumstance[C] // The 7th International Conference on Zinc and Zinc Alloy Coated Steel Sheet. Osaka: the Iron and Steel Institute of Japan, 2007: 230-235.
[25] 蒋浩民, 陈新平, 俞宁峰, 等. 正压力和滑动速度对镀锌钢板摩擦系数的影响[J]. 锻压技术, 2005(z1): 129-132.
JIANG H M, CHEN X P, YU N F, et al.Effects of Contact Pressure and Sliding Velocity on the Frictional Coefficient of Zinc-coated Sheets[J]. Forging and Stamping Technology, 2005(z1): 129-132.
[26] 蒋浩民, 俞宁峰, 陈新平, 等. 温模条件下镀锌钢板摩擦行为研究[J]. 塑性工程学报, 2006, 13(1): 40-42.
JIANG H M, YU N F, CHEN X P, et al.Study on the Frictional Behavior of Zinc-Coated Sheet in Warm Die[J]. Journal of Plasticity Engineering, 2006, 13(1): 40-42.