Search Results

Tailor welded blanks offer an excellent opportunity to reduce manufacturing costs, decrease vehicle weight, and improve the quality of sheet metal stampings. However, tearing near the weld seam is a concern in Tailor Welded Blanks due to material changes in the fusion and heat affected zones of the weld. Therefore, data is required such as the potential strain of the material in these areas to use in the process design. For example, Cao and Kinsey proposed a modification to the deep drawing process where segmented dies with local adaptive controllers clamp adjacent to the weld line during the forming operation thereby reducing the strain in the material near the weld seam and in turn the concern of tearing failure. In order to aid in the design process for this modification, an understanding of the effects of the welding process on material changes near the weld seam is essential.

Tailor welded blanks (TWBs) offer an excellent opportunity to reduce manufacturing costs, decrease vehicle weight, and improve the quality of auto body stampings. However, tearing near the weld line and wrinkling in the die addendum often occurs when a traditional forming process is used to fabricate this type of blank. Cao and Kinsey [1] proposed a modification to the stamping process where a mechanism would clamp on the weld line during the deep drawing process to improve the formability of TWBs. Critical to the success of this proposed modification is the ability of the clamping mechanism to perform its intended function and avoid creating adverse effects in the forming process. In this paper, numerical simulations verify the ability of the clamping mechanism to hold the weld line in place during forming and not severely deform the blank in the area of the clamping mechanism.

Tailor welded blanks offer a unique opportunity to reduce manufacturing costs, decrease vehicle weight, and improve the quality of stampings through the consolidation of multiple formed, then welded, parts into a single stamping. However, tearing near the weld line often occurs in this type of blank when formed with a traditional deep drawing process. Therefore, some adaptation to the existing sheet metal forming process must be developed in order to reap the numerous benefits available from tailor welded blanks. In this paper, numerical simulation are presented for a newly contrived tailor welded blank forming process where several hydraulic mechanisms apply distinct clamping forces along the weld line during forming. Excellent results demonstrate the effectiveness of the proposed method.