Sensitivity Analysis on Effect of Parent Materials Parameter on Formability of Tailor Welded Blank

2010 ◽  
Vol 26-28 ◽  
pp. 1177-1183
Author(s):  
Xin Yang Tao ◽  
Jian Ping Lin ◽  
Shui Sheng Chen
Keyword(s):  
Weld Line ◽  
Range Analysis ◽  
Parent Materials ◽  
Orthogonal Experiments ◽  
Anisotropy Index ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Different Thickness ◽  
Strain Hardening Index ◽  
Line Movement

The parent sheet selection in TWB designing is largely dependant on the effect of parent materials parameters on formability of TWBs. Experiments and FE simulations were performed to study the effect of material parameters of TWB’s parent sheets such as t (thickness ratio), k (strength factor of materials), n (strain hardening index), r (anisotropy index) on LDH and weld-line movement of TWB. Orthogonal experiments and range analysis were used to analyze the sensitivity on effect of different parameter on LDH and weld-line movement. The results show that LDH of TWB decreases with increasing ration of stronger sheets parameters to weaker ones, and the rate decreases gradually; in contrary, weld-line movement increases and the increasing rate decreases gradually. Furthermore, different parameters make various contributions to LDH and weld-line movement of TWBs and the effect degree of each parameter changes with different thickness ratios.

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.

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.

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.

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.

Numerical Simulation and Experimental Study on the Weld-Line Movement of Tailor-Welded Blank

2010 ◽  
Vol 97-101 ◽  
pp. 357-360 ◽  
Author(s):  
Xiu Li Hu ◽  
Hao Zhao ◽  
Zhong Wen Xing
Keyword(s):  
Numerical Simulation ◽  
Influence Factors ◽  
Weld Line ◽  
Forming Process ◽  
Forming Technology ◽  
Element Simulation ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Line Movement ◽  
Main Influence

TWB and its forming technology play important role in lightweight manufacturing for the automobile parts. The weld-line movement during TWB forming process affects the product quality greatly. In this paper, two main influence factors of the movement, BHF and the blank thickness at the both sides of the weld-line, were studied by both the experiments and finite element simulation. The results showed that BHF has significant impact on the weld-line movement, especially when the thickness difference of the blanks in TWB is beyond a certain range. Besides, suitable BHF and thickness of the blanks can not only control the weld-line movement, but also improve the formability of TWB.

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.

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