Sheet Metal Bending Residual Stress Effect on Fatigue Performance of Ultra-High Strength Steels

Abstract:

Increasing usage of the high-strength steels in structural design requires deeper understanding of the residual manufacturing stresses effect on the product service fatigue life. The bending forming process is being examined in this work. High cycle fatigue testing of the specimens before and after the bend shaping is performed by means of the vibrational fatigue method. The manufacturing residual and the fatigue tests stress fields are estimated by means of finite element analysis. The similarity principle is used to compare the fatigue curves constructed for the specimens with different geometries based on their local stress field concentration. A comparison with reference work is provided to support the similarity premise. The implementation of the mean stress correction for the residual stress is evaluated. The goal of this work is to demonstrate a methodological integration of the finite element analysis throughout manufacturing and fatigue testing for accurizing design life estimations. It may also serve as an end-to-end review and provide an outline for similar projects.

• Periodical: Advanced Engineering Forum (Volume 56)
• Pages: 1-22
• DOI: https://doi.org/10.4028/p-UY7tVF
• Online since: June 2025
• Authors: Ilya Men*
• Keywords: Bending, Fatigue, FEA Analysis, High-Strength Steel, Mean Stress, Residual Stress, Testing

References

[1] Ömer Necati Cora, Muammer Koç, Promises and problems of ultra/advanced high strength steel (U/AHSS) utilization in automotive industry, Conference: 7th Automotive Technologies Congress, May 2014

[2] Anu Väisänen, Kari Mäntyjärvi, Jussi A. Karjalainen, Bendability of Ultra-High-Strength Steel, Key Engineering Materials Vols. 410-411 (2009) pp.611-620, Trans Tech Publications, March 2009

DOI: 10.4028/www.scientific.net/KEM.410-411.611

[3] S. Gothivarekar, S. Coppieters, R. Talemi, D. Debruyne, Effect of bending process on the fatigue behaviour of high strength steel, ScienceDirect, Journal of Constructional Steel Research, Volume 182, July 2021

DOI: 10.1016/j.jcsr.2021.106662

[4] Serope Kalpakjian, Manufacturing processes for engineering materials, Sheet-Metal Forming Processes, January 1985

DOI: 10.1007/BF02833667

[5] A. Ince, A mean stress correction model for tensile and compressive mean stress fatigue loadings, Fatigue & Fracture of Engineering Materials & Structures (FFEMS), Volume 40, Issue 6, pp.939-948, November 2016

DOI: 10.1111/ffe.12553

[6] Ilya Men, Dmitry Naroditsky, Vibration Fatigue Testing Procedure of High Strength MARS 600 Steel, Fillet Welds Using Stainless Steel Consumable Electrode, Scientific.Net, Advanced Engineering Forum, Volume 49, pp.57-78, May 2023

DOI: 10.4028/p-o0a804

[7] Dr. P. V. R. Ravindra Reddy, G. Chandra Mohan Reddy, A Review on Finite Element Simulations in Metal Forming, International Journal of Modern Engineering Research (IJMER), Vol.2, Issue.4, July-August 2012, pp.2326-2330, ISSN: 2249-6645

[8] C. Jiménez-Peña, C. Goulas, B. Rossi d, D. Debruyne, Influence of hole-making procedures on fatigue behaviour of high strength steel plates, Journal of Constructional Steel Research, Volume 158, pp.1-14, March 2019

DOI: 10.1016/j.jcsr.2019.03.005

[9] S. Gothivarekar, S. Coppieters, R. H. Talemi, D. Debruyne, Experimental Model Validation and Fatigue Behaviour of Cold-Formed High Strength Steel, Multidisciplinary Digital Publishing Institute (MDPI), Proceedings, Volume 2, Issue 8, May 2018

DOI: 10.3390/ICEM18-05200

[10] Yu Xia, Chu Ding, Zhanjie Li, Benjamin W. Schaferb, Hannah B. Bluma, Numerical modelling of stress-strain relationships for advanced high strength steels, Journal of Constructional Steel Research, Volume 182, July 2021, DOI: org/

DOI: 10.1016/j.jcsr.2021.106687

[11] V. Narayanamurthy, C. Lakshmana Rao, B.N. Rao, Numerical Simulation of Ballistic Impact on Armour Plate with a Simple Plasticity Model, DESIDOC, Defence Science Journal, Vol. 64, No. 1, January 2014, pp.55-61

DOI: 10.14429/dsj.64.4521

[12] Kalle Lipi¨ainen, Antti Kaijalainen, Antti Ahola, Timo Bj¨ork, Fatigue strength assessment of cut edges considering material strength and cutting quality, International Journal of Fatigue, Volume 149, April 2021

DOI: 10.1016/j.ijfatigue.2021.106263

[13] Bimal Das1 | Akhilendra Singh1 | Surajit Kumar Paul1, Correlation between fatigue response of preformed bendDP600 steel specimen and wheel disc, Fatigue & Fracture of Engineering Materials and Structures (FFEMS), pp.1-12, June 2020

DOI: 10.1111/ffe.13299

[14] Aki-Petteri Pokkaa, Anna-Maija Arolaa, Antti Kaijalainena, Vili Kestib, Jari Larkiolaa, Strain distribution during air bending of ultra-high strength steels, ESAFORM, March 2021, DOI: org/

DOI: 10.25518/esaform21.2509

[15] ANSYS Inc, Century Dynamics, AUTODYN, Explicit Software for Nonlinear Dynamics, Theory Manual, 2005, Revision 4.3

[16] Maziar Ramezani, Zaidi Mohd Ripin, Roslan Ahmad, Modelling of kinetic friction in V-bending of ultra-high-strength steel sheets, The International Journal of Advanced Manufacturing and Technology, Volume 46, pp.101-110, April 2008

DOI: 10.1007/s00170-008-1450-4

[17] R. Srinivasan, D. Vasudev, P. Padmanabhan, Influence of friction parameters on spring back and bend force in air bending of electrogalvanized steel sheet: an experimental study, The Brazilian Society of Mechanical Sciences and Engineering, Volume 36, pp.371-376, September 2013

DOI: 10.1007/s40430-013-0097-8

[18] Vitalii Vorkov, Dirk Vandepitte, Joost R. Duflou, Finite element modelling of large radius bending operation, International Journal of Manufacturing Research, Volume 15, No. 4, pp.297-320

DOI: 10.1504/IJMR.2020.110518

[19] Min Zhang, Xitian Tian, Residual stresses and strains analysis in press-braking bending parts considering multi-step forming effect, Institution of Mechanical Engineers, Journal of Engineering Manufacture, SAGE, Volume 234, Issue 4, November 2019

DOI: 10.1177/0954405419883053

[20] S. Gothivarekar1, S. Coppieters1, A. Van de Velde1, D. Debruyne1, Advanced FE model validation of cold-forming process using DIC: Air bending of high strength steel, International Journal of Material Forming, January 2020, DOI: org/

DOI: 10.1007/s12289-020-01536-1

[21] Richard Aerensa, Vitalii Vorkovb, Joost R. Dufloub, Physics of large radius air bending, ELSEVIER, ScienceDirect, Procedia Manufacturing 29, Volume 29, pp.161-168, January 2019

DOI: 10.1016/j.promfg.2019.02.121

[22] Vitalii Vorkov1, Richard Aerens, Dirk Vandepitte1, Joost R. Duflou1, The Multi-Breakage Phenomenon in Air Bending Process, Key Engineering Materials, Vols 611-612 (2014), pp.1047-1053, May 2014

DOI: 10.4028/www.scientific.net/KEM.611-612.1047

[23] Tommy J. George, Jeremy Seidt, M.-H. Herman Shen, Theodore Nicholas, Charles J. Cross, Development of a novel vibration-based fatigue testing methodology, International Journal of Fatigue, Volume 26, pp.477-486, October 2003

DOI: 10.1016/j.ijfatigue.2003.10.012

[24] Gyoko Oh, Notch fatigue fracture and crack growth behaviours on a steel sheet under out-of-plane bending, Engineering Fracture Mechanics, Volume 279, February 2023

DOI: 10.1016/j.engfracmech.2023.109062

[25] Yuki Banno, Experimental investigation of fatigue strength of out-of-plane gusset welded joints under variable amplitude plate bending loading in long life region, Welding in the World, Volume 66, pp.1883-1896, June 2022

DOI: 10.1007/s40194-022-01312-6

[26] Karel Raz, Miloslav Kepka, Julie Volkmannova, Vibration Fatigue - FEM analysis vs. Real testing, MM SCIENCE JOURNAL, November 2020

DOI: 10.17973/MMSJ.2020_11_2020045

[27] Gyoko Oh, Yoshiaki Akiniwa, Mean and residual stress effects on fatigue behavior in a pre-strained corner of stainless-steel sheet, ScienceDirect, International Journal of Fatigue, Volume 145, April 2021

DOI: 10.1016/j.ijfatigue.2020.106125

[28] Vladimir Milovanovi´c, Dušan Arsi´c, Miroslav Milutinovi´c 2, Miroslav Živkovi´ and Marko Topalovi´c, A Comparison Study of Fatigue Behavior of S355J2+N, S690QL and X37CrMoV5-1 Steel, Multidisciplinary Digital Publishing Institute (MDPI), Metals, December 2022

DOI: 10.3390/met12071199

[29] T. Hassan, Z. Liu, On the difference of fatigue strengths from rotating bending, four-point bending, and cantilever bending tests, International Journal of Pressure Vessels and Piping, January 2001, pp.19-30

DOI: 10.1016/S0308-0161(00)00080-6

[30] Ilya Men, Force Controlled Low Cycle Fatigue (LCF) Life Evaluation Methodology Based on Unstabilized Material Properties, Scientific.net, Advanced Engineering Forum, Volume 43, pp.17-32, November 202

DOI: 10.4028/www.scientific.net/AEF.43.17

[31] Ayad Mutafi, J.M. Irwan, et. All, Residual stresses in cold-formed steel sections: An overview of influences and measurement techniques, Forces in Mechanics, Volume 18, February 2025

DOI: 10.1016/j.finmec.2025.100306

[32] North American specifications for the design of cold-formed steel structural members. American Iron and Steel Institute, ANSI AISI100-2016, (2016)