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High strength steels are widely used for lightweight automobile parts and the control of springback is very important in sheet metal forming. The object of this study is to develop the forming process for stair type side sill made of high strength steel, DP780. Stair type side sill with local formed area and geometry change area can improve stiffness and design freedom but there are few studies for forming process. The forming technology considered in this paper is form type process, which has many advantages for forming of high strength steel compared with draw type process. Finite element analysis is carried out to predict formability and springback. It is shown that angle calibration of die is essential for reducing springback, and local forming involving bead is effective to control springback also. The effectiveness of local forming and angle calibration is verified by experimental.

A Study on the Forming Process of Stair Type Side Sill for Automobile using DP780