Springback Assessment and Compensation of Tailor Welded Blanks

Springback Assessment and Compensation of Tailor Welded Blanks

Author: Ab Abdullah

Publisher: CRC Press

Published: 2022-12-27

Total Pages: 309

ISBN-13: 1000821943

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Focusing on techniques developed to evaluate the forming behaviour of tailor welded blanks (TWBs) in sheet metal manufacturing, this edited collection details compensation methods suited to mitigating the effects of springback. Making use of case studies and in-depth accounts of industry experience, this book gives a comprehensive overview of springback and provides essential solutions necessary to modern-day automotive engineers. Sheet metal forming is a major process within the automotive industry, with advancement of the technology including utilization of non-uniform sheet metal in order to produce light or strengthened body structures. This is critical in the reduction of vehicle weight in order to match increased consumer demand for better driving performance and improved fuel efficiency. Additionally, increasingly stringent international regulations regarding exhaust emissions require manufacturers to seek to lighten vehicles as much as possible. To aid engineers in optimizing lightweight designs, this comprehensive book covers topics by a variety of industry experts, including compensation by annealing, low-power welding, punch profile radius and tool-integrated springback measuring systems. It ends by looking at the future trends within the industry and the potential for further innovation within the field. This work will benefit car manufacturers and stamping plants that face springback issues within their production, particularly in the implementation of TWB production into existing facilities. It will also be of interest to students and researchers in automotive and aerospace engineering.


Stress Behaviour of Tailor Welded Blanks for Dissimilar Metals Using Finite Element Method

Stress Behaviour of Tailor Welded Blanks for Dissimilar Metals Using Finite Element Method

Author: Chee Wor Lee

Publisher:

Published: 2013

Total Pages: 61

ISBN-13:

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This project presents the stress analysis on tailor welded blanks for dissimilar metals using finite element method. The application of the tailor welded blanks in automotive industries has a large potential and the critical location on the tailor welded blanks based on the stress analysis is important. The structural modeling of the tailor welded blanks is developed using computer aided design software. The method used for tailor welded blanks are later welding. The effect of different materials combination and different configuration on tailor welded blanks on welding behavior is another importance of this study. Finite element method is used to investigate the stress on the tailor welded blanks. Goldak's double ellipsoid source model is used as the heat source model of the investigation. The changes of power in current and voltages, dissimilar metals of aluminium and steel; and the plate-configuration, L-configuration and T-configuration are investigated in this study. The increase of power increases the hot affected zone and distortion of the plate. The heat is dissipated faster at the aluminium plate compared to steel plate makes the stress concentrated at the steel plate. The stress is distributed outside the welding line for the T-configuration due to the fusion process is not complete.


Encyclopedia of Materials

Encyclopedia of Materials

Author: K. H. J. Buschow

Publisher:

Published: 2001

Total Pages: 1008

ISBN-13:

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Accompanyind CR-ROM conrtains The Encyclopedia of Materials Science and Technology on a web access disc.


Formability Evaluation of Tailor Welded Blanks (TWBs)

Formability Evaluation of Tailor Welded Blanks (TWBs)

Author: Hitansh Singhal

Publisher:

Published: 2020

Total Pages: 114

ISBN-13:

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Numerical models are developed to simulate material behavior in each of these tests. To improve the simulation accuracy, various material models for the base material, the HAZ, and the weld zone are considered. The most accurate model has been used for simulating the behavior of the welded blank in the hat bending and square cup drawing process.


A Combined Approach to Improve and Assess the Formability of Tailor Welded Blanks

A Combined Approach to Improve and Assess the Formability of Tailor Welded Blanks

Author: Brad Lee Kinsey

Publisher:

Published: 2001

Total Pages:

ISBN-13:

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In this dissertation, research is presented that both improves and assesses the formability of TWBs. First, an advanced sheet metal forming process, which utilizes segmented dies with local adaptive controllers, is outlined (Cao and Kinsey 1999). This innovation was shown through both numerical simulations and physical experiments to significantly improve the formability of a test panel by reducing the strain in the weaker material. Then, an analytical model is presented to assess the formability of TWBs, including the expected weld line movement and forming height for a given strain state. The validity of the model was verified through numerical simulations. This analytical tool would be instrumental in assisting design engineers analyze TWB applications prior to costly and time consuming numerical simulations and physical implementation. The research work presented here will allow automobile companies to utilize TWBs to their fullest potential thus creating numerous environmental and economical benefits.


Experimental and Numerical Investigation on Part Thicknesses Effects in Tailor Welded Blank Process

Experimental and Numerical Investigation on Part Thicknesses Effects in Tailor Welded Blank Process

Author: Anas Basri Musthafa

Publisher:

Published: 2013

Total Pages: 58

ISBN-13:

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Tailor welded blank (TWB) is increasingly popular in producing sheet metal components especially for automotive industry. TWBs is employed by using dissimilar material welding which is mainly affected blank thickness and type of material used. This study is focused on the part thickness effects using experimental and numerical method. Thickness of tailor welded sheets plays an important role in sheet metal forming since fracture, wrinkling and weak spots are strongly influenced by material behaviour. In this study, simple heat transfer testing equipment is fabricated to conduct heat transfer experiment. A numerical and experimental study was carried out to investigate the heat transfer characteristic for different thickness of common used type of TWB material. The investigated thicknesses of aluminum 1100 are 1, 2 and 3 mm. Low heat capacity laser is used to measure the temperature distribution in experiment and used to validate FE model. A finite element model (2D) of aluminum 1100 is applied to simulate static heat distribution inside the material for different part thicknesses, heating position and amount of heat. The results shown that the heating region for thicker plate for combination 3 mm with 1 mm is 60 % wider compare to thinner plate with 40 %. Different combination of material thickness requires different heating positions and increasing the thickness of the material is increases the use of heat flux.