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

2006 ◽  
Vol 129 (1) ◽  
pp. 211-215 ◽  
Author(s):  
Matt Bravar ◽  
Neil Krishnan ◽  
Brad Kinsey
Keyword(s):  
Numerical Simulation ◽  
Plane Strain ◽  
Analytical Model ◽  
Weld Line ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Industrial Utilization ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Plane Strain Assumption

Tailor welded blanks (TWBs) 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 hindered the industrial utilization of this blank type for all possible applications. 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 technical brief, an analytical model to predict the initial weld line placement necessary to satisfy the desired, final weld line location and strain at the weld line is used. Results from this model are compared to an experimental, symmetric steel TWB case and a 3D numerical simulation, nonsymmetric aluminum TWB case. This analytical model is an extension of one previously presented, but eliminates a plane strain assumption that is unrealistic for most sheet metal forming applications. Good agreement between the analytical model, experimental, and numerical simulation results with respect to initial weld line location was obtained for both cases. Results for the model with a plane strain assumption are also provided, demonstrating the importance of eliminating this assumption.

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.

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.

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.

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.

The Study on Numerical Simulation of Tailor Welded Blanks on Square Cup Stamping

2011 ◽  
Vol 189-193 ◽  
pp. 3932-3935
Author(s):  
Xiao Gang Qiu
Keyword(s):  
Numerical Simulation ◽  
Plastic Deformation ◽  
Strain Distribution ◽  
Weld Seam ◽  
Element Model ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Different Thickness ◽  
The Finite Element Model

The stamping process of the tailor welded blank(TWB) was simulated by the software of DYNAFORM. The finite element model of a boxy part was founded, and the forming of different thickness and properties of the material was studied. Meanwhile, the influence of weld seam on forming result was analyzed. The results show that the weld seam model which founded by real properties can describe the plastic deformation and strain distribution more exactly in the forming process.

Effect of Punch Profile Radius on Springback in V-Bending of Tailor Welded Blanks Welded in Transverse Direction

2014 ◽  
Vol 592-594 ◽  
pp. 1045-1049
Author(s):  
Vijay Gautam ◽  
Digavalli Ravi Kumar ◽  
Ashish K. Shukla
Keyword(s):  
Weld Line ◽  
Bend Angle ◽  
Interstitial Free ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Tailored Blanks ◽  
Interstitial Free Steel ◽  
Tailor Welded Blank ◽  
Transverse Weld ◽  
Good Agreement

Tailor welded blank (TWB) is an advancement in the field of sheet metal forming in which multiple blanks are welded together to create a single blank prior to forming process. Springback behaviour of TWBs in bending is complex due to thickness or material combination. In this research, the effect of punch profile radius on the springback of transversely welded strips has been investigated in V-bending operation with included bend angle of 90° and using punches with three different punch profile radii of 7.5, 10and 12.5 mm. TWBs were prepared by laser welding of interstitial-free steel blanks with a thickness combination of 0.6 and 1.2mm. The Tensile properties of parent materials and tailored blanks were evaluated by Tension test as per ASTM-E8M standard. The bend samples with transverse weld line were prepared to a size of 20X150mm to ensure plane strain bending. Finite element (FE) simulations were performed using Abaqus and were found to be in good agreement with the experimental results.

Formability Enhancement for Tailor-Welded Blanks Using Blank Holding Force Control

2003 ◽  
Vol 125 (3) ◽  
pp. 461-467 ◽  
Author(s):  
Sijun He ◽  
Xin Wu ◽  
S. Jack Hu
Keyword(s):  
Finite Element ◽  
Analytical Model ◽  
Strain Distribution ◽  
Weld Line ◽  
Finite Element Simulations ◽  
Stress Strain ◽  
Tailor Welded Blanks ◽  
Blank Holding Force ◽  
Weld Line Movement ◽  
Line Movement

Tailor-welded blanks (TWB) are widely used for stamped auto body panels because of their great benefits in weight and cost reduction. However, the weld line in a tailor-welded blank causes serious concerns in formability because of material discontinuity and additional inhomogeneous stress/strain distribution. This paper proposes a blank holding force (BHF) control strategy to control the weld line movement, distribute the deformation more uniformly and thereby improve TWB formability. The control methodology is developed based on a simplified 2-D sectional analytical model that estimates the stress/strain distribution and the BHFs required for each side of the flange with dissimilar materials. The model can be further extended to 3-D analysis by superimposing the 2-D sectional analysis results around the entire binder ring and thus determining the required BHF for the whole panel. Finite element simulations are performed to study the effects of forming parameters on the weld line movement. Experiments have been conducted to verify the analytical model and partial finite element simulations. Both analysis and experiments demonstrated that a lower BHF should be applied on the thicker blank side to allow more metal to flow-in for obtaining more uniform strain distribution. The proposed BHF control is proven to be a good approach to enhancing TWB formability.

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.

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