Investigations on Dimensional Accuracy of Stamped Tailor Welded Blanks Under Warm Forming Conditions

2017 ◽  
Author(s):  
Vakada Venkata Naga Satya Suresh ◽  
Srinivasa Prakash Regalla
Keyword(s):  
Stainless Steel ◽  
Sheet Material ◽  
Dimensional Accuracy ◽  
Warm Forming ◽  
Thickness Variation ◽  
Geometric Accuracy ◽  
Spring Back ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Simulation Results

This work emphasizes on the geometric and dimensional accuracy of cylindrical tailor welded blank (TWB) components manufactured under warm forming conditions. In this work, TWB sheet material made of austenitic stainless steel (ASS 304 Grade) and deep drawing steel (IS 513 grade) materials were TIG welded before subjecting to stamping operation. Numerical simulations were validated with experimental results. Simulation results were analyzed to check the thickness variation and stress distribution within the component which otherwise would be difficult to measure experimentally. Measurements in terms of geometric accuracy gave encouraging results. The roundness and perpendicularity measurements indicated better accuracy whereas, cylindricity value has slightly improved. However, dimensional accuracy of the parts in terms of thinning, cup height and diameter has deteriorated. It was found that the spring back effect played a significant role in the deterioration of dimensional accuracy. Presence of residual stresses might be the cause for this effect; further studies are needed to address this issue.

scholarly journals Optimization of Spring Back in Air V Bending Processing using Taguchi and RSM Method

Mechanika ◽  
2020 ◽  
Vol 26 (1) ◽  
pp. 73-81
Author(s):  
Mustafa özdemir
Keyword(s):  
Experimental Data ◽  
Dual Phase Steel ◽  
Sheet Material ◽  
Optimal Combination ◽  
Dual Phase ◽  
Spring Back ◽  
Signal To Noise ◽  
Surface Method ◽  
Bending Process ◽  
Simulation Results

In this study, springback behaviour of Dp600 (Dual Phase Steel) sheet material was investigated using air V bending technique.  As bending parameters, four different punch tip radii and four different sheet thicknesses were used. The springback values obtained from the experiments were compared with each other. At the same time, the experimental data were analysed with Response Surface Method (RSM) and Taguchi (L16) orthogonal array. The experimental data and the simulation results were found to be consistent. The signal-to-noise (S/N) ratio is used to determine the most appropriate parameter of minimum springback behaviour. Additionally, it is possible to estimate the optimal combination of the bending parameters. The signal-to-noise (S/N) ratio and the design of experiment (DOE) were utilised for the analysis of the experimental results. It was determined that the effect of these parameters on the air V bending process was based on springback behaviours.

The Forming Limits Prediction Model for Tailor Welded Blank with Straight Seam

2010 ◽  
Vol 26-28 ◽  
pp. 493-497
Author(s):  
Hao Bin Tian ◽  
Xiao Hang Liu ◽  
Jian Ping Lin ◽  
Xian Ping Liu
Keyword(s):  
Prediction Model ◽  
Analytical Method ◽  
Deformation Characteristic ◽  
Forming Limit ◽  
Forming Limits ◽  
Tailor Welded Blanks ◽  
Base Materials ◽  
Tailor Welded Blank ◽  
Light Weighting ◽  
Simulation Results

The forming of tailor-welded blank is an important technology to body light weighting. While it is difficult to predict the forming limits of tailor welded blanks with different base materials or thickness. For the expanding experiments, an analytical method to predict forming limit height of tailor-welded blanks is established based on the deformation characteristic and plastic theory, and verified by simulation results. This method is not only provided a path to predict forming limit of tailor welded blanks but also provided references to the design of tailor weld parts.

An Analytical Model for Tailor Welded Blank Forming

2003 ◽  
Vol 125 (2) ◽  
pp. 344-351 ◽  
Author(s):  
Brad L. Kinsey ◽  
Jian Cao
Keyword(s):  
Analytical Model ◽  
Weld Line ◽  
Manufacturing Costs ◽  
Environmental Friendliness ◽  
Tailor Welded Blanks ◽  
Die Surface ◽  
Tailor Welded Blank ◽  
Simulation Results ◽  
Weld Line Movement ◽  
Line Movement

Tailor Welded Blanks (TWBs) offer several notable benefits including decreased part weight, reduced manufacturing costs, increased environmental friendliness, and improved dimensional consistency. In order to take advantage of these benefits, however, designers need to overcome the reduced formability of TWBs and be able to accurately predict unique characteristics related to TWB forming early in the design process. In this paper, an analytical model to predict the weld line movement and forming height for a uniform binder force, TWB forming application is presented. Comparison to numerical simulation results demonstrates the accuracy of this methodology. The analytical model provides designers a valuable tool to determine the location of steps on the die surface to accommodate the weld line movement and the potential forming height for a TWB forming with a uniform binder force. The methodology presented here has the potential to be extended to analyze a non-uniform binder force forming of TWBs.

Research on the Spring-Back Compensation Method of Tailor Welded Blank U-Shaped Part

2013 ◽  
Vol 373-375 ◽  
pp. 1970-1974
Author(s):  
Xiao Jing Liu ◽  
Miao Zhang ◽  
Xue Huan Huo ◽  
Xi Jun Ge ◽  
Bo Liu
Keyword(s):  
Compensation Method ◽  
Spring Back ◽  
Simulation Research ◽  
Tailor Welded Blanks ◽  
Mould Surface ◽  
Compensation Factor ◽  
Forming Precision ◽  
Forming Characteristics ◽  
Tailor Welded Blank ◽  
Automotive Panels

Tailor welded blanks stamping forming technology of automotive panels has been widely used in the lightweight of automobile. The simulation research on forming and spring-back of tailor welded blank U-shaped parts was done to analyze the influence of various parameters on the spring-back and find a way to improve forming properties of tailor welded blank U-shaped parts. The optimal analysis method of combining numerical simulation with experiment was adopted to explore the influence of compensation factor on the forming precision. Finally, a reasonable initial iteration compensation factor was found to compensate the mould surface directly. Aiming at forming characteristics of tailor-welded blanks, a segmented compensation method was proposed and used on the U-shaped parts which can improve the precision of components effectively.

scholarly journals Sustainability aspects in the warm forming of tailor welded blanks

2020 ◽  
Vol 184 ◽  
pp. 01042
Author(s):  
V.V.N. Satya Suresh ◽  
A. Suresh ◽  
S.P Regalla ◽  
P.V Ramana ◽  
O. Vamshikrishna
Keyword(s):  
Raw Materials ◽  
Weld Line ◽  
Hydraulic Press ◽  
Warm Forming ◽  
Tailor Welded Blanks ◽  
Long Time ◽  
Body In White ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Line Movement

Tailor welded blank (TWB) technology has been used in the manufacture of automobile body-in-white components since a long time. These components consist of different materials/thicknesses. Researchers and manufacturers involved with production of warm formed TWB components failed to address the sustainable issues related to warm forming. Rather they concentrated more on reducing the weld line movement (WLM). The WLM if not arrested shall lead to fracture, due to wrinkles, produced during forming. In this paper, the sustainability aspects involved in the warm forming of TWB were discussed with respect to energy and material savings. The results show a reduction of about 50% punch load in a hydraulic press during deep drawing under warm forming conditions. This paper addresses the questions related to the implications of thickness ratio on the weld line movement and further shows how material savings of nearly 33% has been obtained. It also discusses about the carbon emissions during manufacturing of raw materials and the recycling benefits of stainless steel, so as to minimize emissions at the production stage itself during raw materials production.

Numerically modeling spring back and spring go amounts and bending deformations of Cr-Mo alloyed sheet material

2020 ◽  
Vol 62 (12) ◽  
pp. 1265-1272
Author(s):  
Mustafa Özdemir ◽  
Hakan Dilipak ◽  
Bülent Bostan
Keyword(s):  
Sheet Material ◽  
Spring Back

scholarly journals Investigation of the Thickness Differential on the Formability of Aluminum Tailor Welded Blanks

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 875
Author(s):  
Jie Wu ◽  
Yuri Hovanski ◽  
Michael Miles
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Numerical Model ◽  
Plastic Strain ◽  
Finite Element Model ◽  
Equivalent Plastic Strain ◽  
Element Model ◽  
Dome Height ◽  
Tailor Welded Blanks ◽  
Simulation Results

A finite element model is proposed to investigate the effect of thickness differential on Limiting Dome Height (LDH) testing of aluminum tailor-welded blanks. The numerical model is validated via comparison of the equivalent plastic strain and displacement distribution between the simulation results and the experimental data. The normalized equivalent plastic strain and normalized LDH values are proposed as a means of quantifying the influence of thickness differential for a variety of different ratios. Increasing thickness differential was found to decrease the normalized equivalent plastic strain and normalized LDH values, this providing an evaluation of blank formability.

To the Influence of the Deformation Speed on Hardening Process during the Cold Sheet Forming

2018 ◽  
Vol 284 ◽  
pp. 513-518 ◽  
Author(s):  
Sergey A. Tipalin ◽  
Michael A. Petrov ◽  
N.F. Shpunkin
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Sheet Material ◽  
Thin Sheet ◽  
Hardening Process ◽  
Deformation Speed ◽  
Thin Sheet Material ◽  
Simulation Results ◽  
Hardening Curve ◽  
Material Forming

The accuracy of the simulation results of stamping processes of thin sheet material depends on the correct properties’ specification, namely stamping ability. Experiments have been carried out and the influence of the deformation speed on the hardening exponent during cold sheet metal forming was studied. It was found out, that strain changed 100 times can influence the strain grade of the hardening curve of about 10%. This regularity has been taken into consideration prior to the calculation in any CAE-software for material forming.

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