Fatigue Estimation Using Inverse Stamping

Abstract

Reverse engineering methods like 3D scanning are becoming common in engineering practice. These methods enable engineers to reproduce the original shape of a scanned part. If other properties are required, then other reverse engineering methods can follow. Estimation of fatigue is a tricky task even if the material properties of the base material are known. Fatigue is influenced not only by material properties and the part’s shape but also by technological processes. Fast fatigue life estimation of stamped parts using reverse engineering methods is the target of this paper. The forming process, which has a crucial impact on the fatigue of stamped parts, is considered via inverse stamping. Adaptation of inverse stamping method from shell FEM meshes to volumetric meshes is included. The article also discusses the application of two methods, the Material Law for Steel Sheets (MLSS) and the Method of Variable Slopes (MVS). These methods adjust the fatigue curve based on effective plastic strain calculated by inverse stamping. Calculated results were compared with experimental results. In most situations, there is a good agreement between the calculations and the tests of the specimens without surface coatings. Sometimes, the calculated results are more conservative than the experiments. This is acceptable in component design in terms of reliability. When a Zn-Ni surface coating was applied, the fatigue life of the specimen decreased.