A comparison study on the effectiveness of stepped binder and weld line clamping pins on formability improvement for tailor-welded blanks

2008 ◽  
Vol 207 (1-3) ◽  
pp. 204-210 ◽  
Author(s):  
W. Chen ◽  
G.S. Lin ◽  
S.J. Hu
Keyword(s):  
Weld Line ◽  
Comparison Study ◽  
Tailor Welded Blanks

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.

Study on Formability Characteristics of the Weld Seam of Aluminum Steel Tailored Hybrid Blanks

2013 ◽  
Vol 549 ◽  
pp. 302-310 ◽  
Author(s):  
Ozan Singar ◽  
Marion Merklein
Keyword(s):  
Automobile Industry ◽  
Weld Seam ◽  
Weld Line ◽  
Tensile Tests ◽  
Forming Process ◽  
Manufacturing Costs ◽  
Tailor Welded Blanks ◽  
Welding Technology ◽  
Tailored Blanks ◽  
Cmt Welding

Tailor Welded Blanks (TWB) are characterized by the fact that sheets with different material qualities and/or thicknesses are welded together before the forming process. The application of TWBs in the automobile industry brings several advantages, such as the reduction of car body weight and manufacturing costs, as well as the integration of several drawing parts into one part. Despite several established tailor welded blanks types, a new version has emerged: The Tailored Hybrid Blanks (THB). The current investigation focuses on tailored hybrid blanks joined by the CMT-welding technology. The main aim of this study is to specify the mechanical properties as well as the formability of Aluminum Steel Tailored Blanks. Steel (HX340LAD, 0.8 mm) sheets covered by different zinc coat thicknesses were combined with an aluminum alloy (AA6014-T4, 1.2 mm). In order to determine the material properties and to analyze the Heat Affected Zone (HAZ), microhardness measurements were taken transversal and longitudinal to the weld line. Results indicate a change of hardness and a very small HAZ. Tensile tests (perpendicular to weld line) and Nakajima tests with online deformation analyses show that the main formation takes place on the aluminum side.

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.

Effect of Weld Location, Orientation, and Strain Path on Forming Behavior of AHSS Tailor Welded Blanks

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
S. K. Panda ◽  
J. Li ◽  
V. H. Baltazar Hernandez ◽  
Y. Zhou ◽  
F. Goodwin
Keyword(s):  
Plane Strain ◽  
Weld Line ◽  
High Strength ◽  
Deformation Mode ◽  
Dome Height ◽  
Manufacturing Cost ◽  
Stretch Forming ◽  
Material Combination ◽  
Tailor Welded Blanks ◽  
The Difference

Use of multiple advanced high strength steel sheets for fabrication of tailor welded blanks (TWBs) is one of the current interests for automotive and steel industries as it reduces manufacturing cost and weight of the vehicle, and also improves the quality of the component. As the varieties of TWB applications are increasing, the effects of the difference in material properties, weld, and its orientation on blank formability have become important both in deep drawing and stretch forming. In this work, high strength low alloy (HSLA) grade steels were laser welded with two different dual phase steels having 980 MPa (DP980) and 600 MPa (DP600) tensile strengths to fabricate two different material combination TWBs (DP980-HSLA and DP600-HSLA). Formability of these two types of TWBs has been studied experimentally both in biaxial and plane strain stretch forming modes by performing limiting dome height (LDH) tests using a 101.6 mm diameter hemispherical punch. Five different weld locations during biaxial-stretch forming mode, and the effect of weld orientation with respect to major principal strain in plane strain stretch forming mode, have been studied. It was found that formability LDH and failure location depended on weld location, and LDH increased when weld line was positioned at the extreme positions away from the center due to more uniform strain distribution on the deformed dome. The welded blanks had lower formability in plane strain deformation mode compared with biaxial-stretch forming mode. However, influence of weld orientation on the formability depended on material combination. Changes in the fracture mode were confirmed from fractography analysis of biaxial, transverse plane strain, and longitudinal plane strain stretch formed samples.

Effect of Weld Line Direction and Its Position on Drawing Performance of Tailor-Welded Blanks

2011 ◽  
Vol 697-698 ◽  
pp. 399-403
Author(s):  
W.J. Cao ◽  
Y.C. Jia ◽  
An Ping Xu ◽  
A.W. Xu ◽  
Y.X. Qu
Keyword(s):  
Relative Position ◽  
Weld Line ◽  
Drawing Force ◽  
Key Factors ◽  
Tailor Welded Blanks ◽  
Automotive Panels ◽  
Line Direction

Nowadays, the tailor-welded blanks (TWBs) technology has been developing very rapidly in China. The quality of tailor-welded blanks becomes more and more important for the stable manufacturing of automotive panels. therefore, it’s very necessary to find out the key factors that influence the forming performance of tailor-welded blanks. This paper experimentally studies the effect of weld line direction on drawing performance. The tailor-welded blanks with the same material pair were used in the experiment, in which the weld line is straight and forms a certain angle with drawing force. The drawing tests were done with the different angles and values of relative position. The results show that the forming performance is related to the relative position of weld line and the angle between weld line and drawing force.

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.

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