Comparison between laser beam and gas tungsten arc tailored welded blanks via deep drawing

2020 ◽  
pp. 095440542096239
Author(s):  
Ahmad Aminzadeh ◽  
Ali Parvizi ◽  
Rasoul Safdarian ◽  
Davood Rahmatabadi
Keyword(s):  
Laser Beam ◽  
Base Metal ◽  
Deep Drawing ◽  
Weld Zone ◽  
Weld Line ◽  
Gas Tungsten Arc ◽  
Tailor Welded Blanks ◽  
Gas Tungsten ◽  
Weld Line Movement ◽  
Line Movement

This paper aims at analyzing the deformation behavior of tailor welded blanks (TWBs), manufactured by laser beam welding (LBW) and gas tungsten arc welding (GTAW), through the deep drawing process. Dissimilar and similar steels with different thicknesses were used in the production of tailor welded blanks. The Nd: YAG laser welding method with nitrogen (N2) as the shielding gas was used to join TWBs. The effects of some significant process factors, namely welding speed, blank holder forces (BHF), material properties of base metals, dry/lubricated condition and laser spot size was experimentally investigated on the weld line movement and drawing depth. Results indicated that using LBW with optimum parameters for the production of dissimilar TWBs caused the control of failure in the weaker base metal. Results showed that the sound welds were produced in similar TWBs with a thickness ratio of 2 when using GTAW, but the weld quality was poor when using LBW. Moreover, it is observed that the critical stresses were taken place outside of the weld zone and rupture due to the high heat input of laser and metallurgical changes of the base metal that occur in the pre-softening zone. In addition, the weld line movement occurred as a result of plastic strain change of the weld joint that caused failure-prone zone creation as well as the adverse wrinkling.

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.

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.

Theoretical and experimental investigation of deep drawing of tailor-welded IF steel blanks with non-uniform blank holder forces

2016 ◽  
Vol 231 (2) ◽  
pp. 286-300 ◽  
Author(s):  
Mohammad Hossein Asadian-Ardakani ◽  
Mohammad Reza Morovvati ◽  
Mohammad Javad Mirnia ◽  
Bijan Mollaei Dariani
Keyword(s):  
Deep Drawing ◽  
Weld Line ◽  
Body Parts ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Tension Distribution ◽  
Strip Drawing ◽  
Parts Manufacturing ◽  
Weld Line Movement ◽  
Line Movement

Tailor-welded blank is one of the promising technologies in the application of lightweight materials for auto body parts manufacturing. The material discontinuity across the weld line results in an inhomogeneous deformation and weld line displacement. In this study, a two-dimensional analytical model is proposed to predict the tension distribution along the cross section. An energy method is used to calculate the restraining force due to bending, sliding, and unbending phenomena on the die and punch radii. To control the weld line movement, a blank holder force control strategy is proposed to achieve force equilibrium at the bottom of the part across the weld line. Finite element simulations are performed to study the effect of die and punch radii, friction coefficient, thickness ratio, and blank holder forces on the weld line displacement in strip drawing process. Under a uniform blank holder force, the weld line moves toward the thicker/stronger side implying a higher blank holder force is required for the thinner/weaker side. The results show that the weld line displacement can be controlled by an appropriate blank holder force adjustment. In order to control the weld line movement in square cup deep drawing, blank holder force on the thinner side is increased and its influences on the deformation process are investigated. Comparisons of material draw-in, weld line movement, and forming force show a good agreement between the theoretical, numerical, and experimental results.

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.

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.

Influence Principles of Linear-Weld-Line Tailor-Weld Blanks’ Formability with Different Thickness of Base Metals

2014 ◽  
Vol 556-562 ◽  
pp. 507-510
Author(s):  
Yong Gan ◽  
Han Chao Wang
Keyword(s):  
Base Metal ◽  
Great Influence ◽  
Weld Line ◽  
Dome Height ◽  
Forming Process ◽  
Mathematical Expressions ◽  
The Difference ◽  
Weld Line Movement ◽  
Different Thickness ◽  
Line Movement

Discussing the influence between the linear-weld-line TWBs’ different thickness of base metal and the formability of sheet by Dynaform FEM simulations technology and Dome test. Meanwhile, the correlation with the difference thickness of base metal and the limit doming height, weld-line movement are proposed, we find that both sides of the TWBs’ thickness have a great influence on the forming process. Then, the mathematical expressions are proposed between the changing thickness of base metal and limiting dome height, weld-line movement by using the genetic algorithm to fit the simulations’ data, which provide an evidence for production in theory.

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