Journal of Failure Analysis and Prevention

, Volume 13, Issue 4, pp 451–462 | Cite as

Understanding the Effects of Mechanical and Laser Cut-Edges to Prevent Formability Ruptures During Automotive Manufacturing

  • Daniel J. Thomas
Technical Article---Peer-Reviewed


The cut-edge condition has an important influence on the formability capacity of high-strength steel (HSS) automotive structures. XF350 and DP600 under examination were observed to display a decreased level of formability in the surface regions because mechanical punched edge hole-flanging capacity is dependent on ductility and the surface quality of the cut-edge produced. Formability was observed to be highly dependent not purely based on the properties of the steel but also the cut-edge properties. Hole expansion capacity (HEC)-forming experiments were performed on flat circular plates with mechanical and laser-cut holes to investigate the fracture and forming limits of HSS. The HEC properties of the cut-edges were determined using mechanical and laser-cutting processes using various cutting process parameters in which certain edge types displayed decreases in edge ductility. It was found that, by altering the processing parameters during the cutting process, the edge quality can be improved, and this has a positive effect on the formability capacity of steel components.


Forming HEC Hole expansion capacity Cut-edge forming 



Elongation to failure


Advanced high-strength steel


Hole expansion capacity


High-strength low alloy


High-strength steel


Arithmetic mean of departures from the mean line


Maximum height of profile above the mean line


Maximum depth of profile below the mean line





The present research was funded by a grant from the Engineering and Physical Sciences Research Council (EPSRC). The author wishes to acknowledge the support by Swansea University College of Engineering and The Engineering Centre for Manufacturing and Materials during the course of this research.


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Copyright information

© ASM International 2013

Authors and Affiliations

  1. 1.Creation Engineering, Llynfi Enterprise CentreHeol-Ty-Gwyn Industrial EstateMaestegUK

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