Numerical Simulation and Multi-Objective Optimization of Partition Cooling in Hot Stamping of the Automotive B-Pillar Based on RSM and NSGA-II

Abstract

In this study, the simulation and optimization of the partition cooling in the hot stamping process was carried out for an automotive B-pillar through minimizing the maximum thickening rate and the maximum thinning rate located in the rapid and slow cooling zones. The optimization was implemented by investigating the process parameters such as friction coefficient, sheet austenitizing temperature, holding time, heating zone temperature, the upper binder force and the lower binder force. The optimal Latin hypercube design (OLHD), the response surface methodology (RSM) and the non-dominated sorting genetic algorithm (NSGA-II) were combined to establish the relationship between process parameters and form quality objectives. After multi-objective optimization, the maximum thickening rate and the maximum thinning rate of the slow cooling zone and rapid cooling zone were 11.1% and 12.4%, 4.7% and 7.1%, respectively. Afterwards, the simulation was performed according to the optimized parameter combinations to analyze the temperature field, microstructure, tensile strength, hardness, thickening rate and thinning rate, and forming quality. Moreover, the hot stamping test and experimental results showed that the microstructure of the ferrite and pearlite structure was uniformly distributed in the slow cooling zone, and its tensile strength reached 680 MPa, the elongation was 11.4% and the hardness was 230.56 HV, while the lath martensite structure was obtained in the rapid cooling zone, with tensile strength of up to 1390 MPa, elongation of about 7.0% and hardness reaching 478.78 HV. The results of thickness, microstructure, tensile strength and the hardness test correspond well with the simulation results.