The Influence of the Punch Speed on the Welding Line Movement during Deep Drawing in Case of Tailor Welding Blanks

2014 ◽  
Vol 1036 ◽  
pp. 355-360
Author(s):  
Aurelian Albut
Keyword(s):  
Deep Drawing ◽  
Cylindrical Shape ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Punch Speed ◽  
Welded Structure ◽  
Welding Line ◽  
Axis Of Symmetry ◽  
Line Movement

The work presented in this paper refers to numerical simulation related to deep drawing of three parts having different geometry, as follows: square shape, cylindrical shape and semispherical shape. The current paper is trying to prove out the important role of the punch speed on the welding line displacement during the forming process. The punch speed influence is testes for the fallowing values: 100, 300, 600, 800 and 1000 mm/s. The punch stroke is 25 mm, which is the safe drawing depth for all three selected shapes. The parts are made from tailor welded blanks, having the welding line positioned as axis of symmetry. It must be mentioned that both materials from the welded structure are having the same thickness (1mm). The Dynaform 5.8.1 software is used to simulate the forming process. The part obtained after each simulation is analyzed and measured to quantify the displacement of the welding line. The welding line behave differently for each tested punch speed and also for each part shape. All the parameters are maintained fixed except the punch speed. The obtained results for those three shapes were compared to realise the behaviour of the tailor welded blanks during deep drawing process. In the final part of this paper conclusions regarding the influence of the punch speed and of the part shape on the welding line movements are presented.

The Influence of the Blank Holder Force on Material Thinning during Forming of a Rectangular Part Made from Tailor Welded Blanks

2014 ◽  
Vol 1036 ◽  
pp. 344-348
Author(s):  
Aurelian Albut ◽  
Vlad Andrei Ciubotariu
Keyword(s):  
Deep Drawing ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Tailor Welded Blanks ◽  
Tailored Blanks ◽  
Welded Structure ◽  
Welding Line

The current work deals with numerical simulation connected to forming of a rectangular shaped part made from tailored blanks, having the welding line positioned symmetrical with respect to the part geometry. The objective was to study the relation between the blank holder force applied during forming and the thinning of the parents materials. All the parameters are fixed except the blank holder force, its variation will cause variation of the material thinning. The presented work is trying to demonstrate the important role of the blank holder force on the material thinning during the deep drawing process. It must be mentioned that both materials from the welded structure are having the same thickness (1mm). The Dynaform 5.8.1 software is used to simulate the forming process. The part obtained after each simulation is analyzed and measured to quantify the on the material thinning. All the parameters are maintained fixed except the blank holder force. The obtained results for five different binder forces (5, 10, 30, 50, 70 kN) were compared to realise the behaviour of the tailor welded blanks during deep drawing process. In the final part of this paper conclusions regarding the influence of the blank holder force on the material thinning are presented.

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.

Study Concerning the Maximal Depth of a Rectangular Part Made from Tailor Welded Blanks

2013 ◽  
Vol 332 ◽  
pp. 369-374
Author(s):  
Aurelian Albut
Keyword(s):  
Base Material ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Base Materials ◽  
Maximal Depth ◽  
Tailored Blanks ◽  
Welding Line ◽  
Paper Work ◽  
Formed Part ◽  
Property Changes

The formability of tailor welded blanks is significantly reduced compared with the homogeneous blanks. One of the important factor that are behind this fact is the material property changes a sides the welding line that merge the base materials. The work presented in this paper deals with numerical simulation concerning forming of a rectangular shaped part made from tailored blanks (TWBs), having the welding line situated symmetrical with respect to the part geometry. Due to dissimilar base materials of the TWBs, it is difficult to predict the maximal depth of the formed part. The presented research is trying to determine the maximal depth of the TWBs part based on the maximal depth of the parts obtained from each base material partly. To simulate the forming process the academically version of the Dynaform 5.8.1 software have been used. The obtained results are presented in the final part of this paper work.

Process Parameter Effects on the LDR in Warm Deep Drawing of Magnesium Alloys

2009 ◽  
Vol 410-411 ◽  
pp. 587-593 ◽  
Author(s):  
Giuseppina Ambrogio ◽  
Luigino Filice ◽  
Archimede Forcellese ◽  
G. Leonardo Manco ◽  
M. Simoncini
Keyword(s):  
Magnesium Alloy ◽  
Deep Drawing ◽  
Experimental Results ◽  
Drawing Ratio ◽  
Experimental Campaign ◽  
Limiting Drawing Ratio ◽  
Warm Deep Drawing ◽  
Punch Speed ◽  
Peak Value

The present work is focused on the investigation of the role of temperature and punch speed in warm deep drawing of AZ31 magnesium alloy. To this purpose, an experimental campaign, defined using a proper DOE approach, has been performed. The experimental results, in terms of the Limiting Drawing Ratio, have shown that drawability is strongly affected by the process parameters. In particular, Limiting Drawing Ratio exhibits the peak value at 250°C. As far as the effect of punch speed is concerned, it depends on temperature: at 200°C drawability increases with decreasing punch speed whilst a reverse behaviour is observed at 250 and 300°C. The experimental results have been analysed by ANOVA in order to evaluate the effect of the single independent factors and their interactions on the dependent one.

Control of Defects in Deep Drawing of Tailor-welded Blanks for Complex Shape Automotive Panel

2021 ◽  
Author(s):  
Hui Wang ◽  
Lizi Liu ◽  
Haibao Wang ◽  
Jie Zhou
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Minimum Distance ◽  
Complex Shape ◽  
Orthogonal Experiment ◽  
Tensile Tests ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Forming Defects ◽  
Automotive Panel

Abstract With the development of lightweight vehicles, tailor welded blanks (TWBs) are increasingly used in the automotive industry. Splitting and wrinkling are the main defects during the deep drawing of TWBs. A new method to control the forming defects was introduced in the forming process of TWBs in this study. The microstructure and mechanical properties of TWBs were characterized through metallography and tensile tests. Finite element modelling of an automobile rear door inner panel made of TWBs was built to analyse deep drawing. Edge cutting and notch cut were introduced in the drawing to deal with forming defects and reduce the number of stamping tools. The minimum distance between the material draw-in and trimming lines, thinning index and thickening index were defined as the measurable index to analyse the numerical results. Orthogonal experiment, numerical simulation and multiobjective experiment were utilised to optimize the forming parameters. The proposed method and optimised parameters were verified through experiments. The experimental results are basically consistent with the numerical simulation. Results demonstrate that the proposed method can provide some guidance for controlling the defects in deep drawing of TWBs for complex shape automotive panel.

Study Concerning the Maximal Depth of a Cylindrical Part Made from Tailor Welded Blanks

2014 ◽  
Vol 657 ◽  
pp. 188-192
Author(s):  
Aurelian Albut ◽  
Valentin Zichil ◽  
Adrian Judele
Keyword(s):  
Research Work ◽  
Cylindrical Part ◽  
Parent Material ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Maximal Depth ◽  
Tailored Blanks ◽  
Welding Line ◽  
Severe Change ◽  
Formed Part

The formability of tailor welded blanks is significantly reduced compared with the homogeneous blanks. This phenomenon is caused by the fact that there is a severe change in the material property sideways the welding line. Within 2-3 mm, in case of laser welding maybe less, there is a gradient of mechanical characteristics of materials. The research work presented in this paper deals with numerical simulation regarding forming of a cylindrical shaped part made from tailored blanks (TWBs), having the welding line situated symmetrical with respect to the part geometry. Due to dissimilar parent materials of the TWBs, it is difficult to anticipate the maximal depth of the formed part. The presented research is trying to determine the maximal depth of the TWBs part based on the maximal depth of the parts obtained from each parent material partly. To simulate the forming process of the cylindrical part the academically version of the Dynaform 5.8.1 software have been used. The obtained results are presented in the final part of this paper work.

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.

Optimization of Deep Drawing Processes Using Statistical Design of Experiments

1996 ◽  
Author(s):  
Dietrich Bauer ◽  
Regine Krebs
Keyword(s):  
Mathematical Model ◽  
Analysis Of Variance ◽  
Orthogonal Array ◽  
Deep Drawing ◽  
Metal Forming ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Metal Forming Process

Abstract For a deep drawing process some important controllable variables (factors) upon the maximum drawing force are analyzed to find a setting adjustment for these process factors that provides a very low force for the metal forming process. For this investigation an orthogonal array L18 with three-fold replication is used. To find the optimum of the process, the experimental results are analyzed in accordance with the robust-design-method according to Taguchi (Liesegang et. al., 1990). For this purpose, so-called Signal-to-Noise-ratios are calculated. The analysis of variance for this S/N-ratios leads to a mathematical model for the deep drawing process. This model allows to find the pressumed optimal settings of the investigated factors. In the following, a confirmation experiment is carried out by using these optimal settings. The maximum drawing force of the confirmation experiment does not correspond with the confidence interval, which was calculated by analysis of variance techniques. So the predicted optimum of the process does not lead to a metal forming process with very low deep drawing force. The comparison with a full factorial plan shows that there are interactions between the investigated factors. These interactions could not be discovered by the used orthogonal array. Thus the established mathematical model does not describe the relation between the factors and deep drawing force in accordance with the practical deep drawing conditions.

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.

Sign in / Sign up

Export Citation Format

Share Document