Combined effect of thickness ratio and selective heating on weld line movement in stamped tailor-welded blanks

2016 ◽  
Vol 32 (12) ◽  
pp. 1363-1367 ◽  
Author(s):  
V. V. N. Satya Suresh ◽  
Srinivasa Prakash Regalla ◽  
Amit Kumar Gupta
Keyword(s):  
Weld Line ◽  
Thickness Ratio ◽  
Combined Effect ◽  
Selective Heating ◽  
Tailor Welded Blanks ◽  
Weld Line Movement ◽  
Line Movement

Minimization of weld line movement in heat-assisted forming of tailor welded blanks

2018 ◽  
Vol 233 (11) ◽  
pp. 3760-3768
Author(s):  
VVN Satya Suresh ◽  
Srinivasa Prakash Regalla ◽  
Amit Kumar Gupta
Keyword(s):  
Weld Line ◽  
Tungsten Inert Gas Welding ◽  
Selective Heating ◽  
Tailor Welded Blanks ◽  
Stamping Process ◽  
Steel Aisi ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Line Movement

In this work, the formability aspects in terms of desired cup height during stamping operation of tailor welded blanks have been studied along with minimizing the movement of weld line. Circular sheets were prepared by joining austenitic stainless steel (ASS 304 Grade) and drawing quality mild steel (AISI 1018) materials with tungsten inert gas welding. To reduce the undesirable weld line movement during stamping process, a novel heat-assisted forming method involving localized and controlled heating of the stronger material side (ASS 304 steel) has been carried out. The experimental setup developed for this purpose enabled heating and maintained the selected zone at the desired temperature during the stamping process. The entire process has been simulated using finite element method and the results obtained were in close agreement with the experimental results. The effect of selective heating of tailor welded blank also resulted in the overall improvement in the quality of the product.

Maximum Bulge Height and Weld Line Displacement in Hydroforming of Tailor Welded Blanks

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
A. Kumar ◽  
V. Gautam ◽  
D. R. Kumar
Keyword(s):  
Weld Line ◽  
Thickness Ratio ◽  
Dome Height ◽  
Interstitial Free ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Hydraulic Bulging ◽  
Weld Line Movement ◽  
Bulge Height ◽  
Line Movement

Tailor welded blank (TWB) has many advantages over a traditional blank for manufacturing automobile sheet metal components, such as significant flexibility in product design, higher structural stiffness, and crash behavior. However, lower formability and weld line movement are some of the problems associated with forming of TWBs. Hydroforming is a potential technique to enhance formability. In this work, the effect of thickness ratio on maximum dome height and weld line movement in hydraulic bulging of laser welded interstitial-free (IF) steel blanks of different thickness combinations has been predicted using finite element (FE) simulations. The results are also validated with hydraulic bulging experiments on TWBs. It has been found that with increase in thickness ratio, the maximum bulge height decreased and weld line displacement toward thicker side increased. These results have been used to relocate the weld line toward the thinner side in the initial blanks and achieve a more uniform bulge profile of the dome. The peak pressure to achieve maximum safe dome height and percentage thinning has also been found out. The results showed huge improvement in uniformity of bulge profile with little reduction in dome height.

Investigation of Weld Line Movement in Tailor Welded Blank Forming

2012 ◽  
Vol 445 ◽  
pp. 39-44 ◽  
Author(s):  
R. Safdarian Korouyeh ◽  
Hassan Moslemi Naeini ◽  
Golam Hosein Liaghat ◽  
M.M. Kasaei
Keyword(s):  
Weld Line ◽  
Thickness Ratio ◽  
Forming Limit ◽  
Strength Ratio ◽  
Line Position ◽  
Tailor Welded Blanks ◽  
Limit Strength ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Line Movement

Weld line movement is one of the important parameters in Tailor Welded Blanks (TWB) forming. Weld line movement is important from some aspects: First, weld line position in the final part is so important because TWB part will be assembled with other parts and weld line movement can influence on assembling. Second, weld line movement which often is towardthe stronger (thicker) metal cause necking and fracture in weaker (thinner) metal. A forming criterion for tailor welded blank will be presented based on the analytical model in this research. This criterion suggests Limit Strength Ratio (LSR) and Limit Thickness Ratio (LTR) for forming limit of TWB.When thickness ratio or strength ratio in tailor welded blank is greater than LTR or LSR, weld line movement will be increased and cause forming decrease. Some simulation tests are done for correction investigation of this theoretical model.

Comparison of Analytical Model to Experimental Results and Numerical Simulations for Tailor Welded Blank Forming

2004 ◽  
Author(s):  
Matt Bravar ◽  
Brad Kinsey ◽  
Neil Krishnan
Keyword(s):  
Numerical Simulations ◽  
Analytical Model ◽  
Weld Line ◽  
Experimental Results ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Industrial Utilization ◽  
Initial Placement ◽  
Weld Line Movement ◽  
Line Movement

Tailor Welded Blanks offer several notable benefits including decreased part weight, reduced manufacturing costs, and improved dimensional consistency. However the reduced formability and other characteristics of the forming process associated with TWBs has limited the industrial utilization of this blank type. One concern with TWB forming is that weld line movement occurs which alters the final location of the various materials in the TWB combination. In this paper, an analytical model to predict the initial weld line placement necessary to satisfy the desired, final weld line location is presented. Good agreement between the model, experimental results, and numerical simulations with respect to weld line movement and initial placement was obtained for a symmetric, steel TWB case and a non-symmetric, Aluminum TWB case.

Methodology and Model to Determine Key Process Parameters for Tailor Welded Blank Forming

2003 ◽  
Author(s):  
Brad Kinsey ◽  
Matt Bravar ◽  
Jian Cao
Keyword(s):  
Analytical Model ◽  
Cross Section ◽  
Weld Line ◽  
Cross Sectional ◽  
Environmental Friendliness ◽  
Sheet Metal Parts ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Line Movement

Tailor Welded Blanks (TWBs) offer several notable benefits compared to traditional sheet metal parts including decreased part weight, reduced manufacturing costs, increased environmental friendliness, and improved dimensional consistency. In order to take advantage of these benefits, however, designers must overcome formability concerns related to stamping TWBs and be able to accurately predict unique characteristics related to the forming of this blank type. In this research, an analytical model using a 2D cross-sectional approach was devised and implemented to predict the weld line movement and forming height for a uniform binder force TWB application. The inputs into the analytical model are the desired strain at the weld line location, the geometry of the 2D cross-section, material properties, and the frictional condition. From this information, the model predicts the stress and strain at several key locations on the 2D cross-section as well as the movement of the material in the binder area and in the formed walls.

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