scholarly journals Control of defects in the deep drawing of tailor-welded blanks for complex-shape automotive panel

2022 ◽  
Author(s):  
Hui Wang ◽  
Lizi Liu ◽  
Haibao Wang ◽  
Jie Zhou
Keyword(s):  
Deep Drawing ◽  
Complex Shape ◽  
Tailor Welded Blanks ◽  
Automotive Panel

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.

scholarly journals WELD MOVEMENT IN DEEP DRAWING OF TAILOR-WELDED BLANKS

2016 ◽  
Vol 2016 (05) ◽  
pp. 1309-1312
Author(s):  
Alexander Schrek ◽  
Pavol Svec ◽  
Veronika Gajdosova
Keyword(s):  
Deep Drawing ◽  
Tailor Welded Blanks

Failure Analysis of a Double Rectangular Deep Drawn Part Using FEM: An Industrial Case

2010 ◽  
Author(s):  
Pedro de Jesu´s Garci´a Zugasti ◽  
Hugo Iva´n Medelli´n Castillo ◽  
Abel Cerino Zapata ◽  
Dirk Frederik de Lange ◽  
Antonio Ca´rdenas Galindo
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Complex Shape ◽  
Industrial Applications ◽  
Design Tool ◽  
Computer Assisted ◽  
Trial And Error ◽  
Trial And Error Method ◽  
Lubrication Conditions ◽  
Error Method

Complex shape deep drawn parts are more frequently used in many industrial applications. However, complex parts can be particularly difficult to form due to serious wrinkling and tearing problems associated to the different forming modes and complex material flow. Moreover, deep drawing depends highly on the part design, including radii, draw depths, wall angles, steps and transitions; these variables interact to affect the cost and quality of the drawing. Since there are not theoretical methods available in the literature yet, and because several factors affect the drawn, deep drawing of complex shapes is usually developed using the trial and error method. To increase the speed of the design process and the machine tuning, and to reduce the use of the trial and error method, computer-assisted analysis and simulations based on numerical approaches such as Finite Element Method (FEM), are more intensively used. By using these computerized methods, process parameters (sheet metal material, lubricants, forces, part geometry etc.) can be reproduced and modified, part defects can be also identified and, if possible, eliminated. This paper presents the analysis of an industrial double rectangular deep drawing kitchen sink using virtual prototyping based on FEM. In the original deep drawing process the part presented defects (cracks). A failure criterion was established to evaluate and reduce the stresses levels that were causing the cracks. An analysis procedure was then proposed and the optimal lubrication conditions were obtained to eliminate the cracks. FEM model, simulations and results, were validated by measuring the thickness of the actual fabricated part. The thickness of the sheet metal at the critical area was measured in the FEM simulation and compared with the thickness profile of the actual fabricated part before and after changes in the lubrication conditions. The results have shown that FEM can be effectively used as a design tool to eliminate part defects in complex shape deep drawing processes.

scholarly journals Effect of Thickness Ratio on Weld Line Displacement in Deep Drawing of Aluminium Steel Tailor Welded Blanks

2014 ◽  
Vol 6 ◽  
pp. 401-408 ◽  
Author(s):  
Arman Khan ◽  
V.V.N. Satya Suresh ◽  
Srinivasa Prakash Regalla
Keyword(s):  
Deep Drawing ◽  
Weld Line ◽  
Thickness Ratio ◽  
Tailor Welded Blanks

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.

Evaluation of Draw Bead Geometry on Deep Drawing of Complex Rectangular Shape Part

2012 ◽  
Vol 445 ◽  
pp. 96-101 ◽  
Author(s):  
S.M. Beimesl ◽  
Amir Mostafapour Asl
Keyword(s):  
Deep Drawing ◽  
Bead Geometry ◽  
Trial And Error ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Surface Method ◽  
Optimization Simulation ◽  
Restraining Force ◽  
Full Factorial ◽  
Automotive Panel

The control of blank-holder force (BHF), is one of the main parameters in deep drawing. Fracture, wrinkling and inappropriate draw-in of sheet edges on certain locations are the main defects that occur due to insufficient and not well distributed restraining force of sheet flow into die cavity by BHF. It was demonstrated that appropriate utilization of draw beads with appropriate geometry and location in die could reduce or even eliminate these defects. Achieving an optimum geometry and location of draw beads are main issues in tooling stage that would cause high cost due to trial and error. In this paper, 2D FE analyses to reach draw bead restraining Force (DBRF) for several usual draw beads geometries were performed. 3D FE analyses of deep drawing process of a rectangular automotive panel with complex and parametric geometry with the presence of draw beads were simulated by the use of ABAQUS6.9 commercial FEM package to reach an optimization of best location and also best geometry. Response surface method with full factorial case was employed for optimization. Simulation results were validated by experimental data of deep drawing.

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