Investigation of The Effects of Process Parameters on The Welding Line Movement in Deep Drawing of Tailor Welded Blanks

Document Type: Original Article

Author

Department of Mechanical Engineering, Faculty of Engineering and Technology, Imam Khomeini International University, Qazvin, Iran

Abstract

In this paper, the deep drawing process of tailor welded blanks is simulated using the finite element modelling and verified using the experimental results available in the literature. Then the effect of die and material properties on the welding line movement is investigated. It is seen that the most effective material parameters on weld line movement are different between sheet metal thicknesses and strength coefficient of two welded sheets. Also it is seen that the most effective die parameter on weld line movement is the friction coefficient between punch and blank. Finite element simulations show that in the wall section of the drawn cup, the welding line moves toward the material with smaller thickness and lower strength coefficient while in the bottom of the drawn cup, the welding line moves toward the material with larger thickness, and higher strength coefficient. Based on the results, increasing the friction coefficient between blank and die, decreases the welding line movement considerably.

Keywords


[1] Choi, Y., Heo, Y., Kim, H. Y., Seo, D., “Investigations of weld-line movements for the deep drawing process of tailor welded blanks”, Journal of Material Processing Technology, Vol.108, No. 1, 2000, pp. 1-7.

[2] Kinsey, B., Liu, Z., Cao, J., “A novel forming technology for tailor-welded blanks”, Journal of Material Processing Technology, Vol. 99, No. 1-3, 2000, pp. 145-153.

[3] Meinders, T., Van den Berg, A., HueÂtink, J., “Deep drawing simulations of Tailored Blanks and experimental verification”, Journal of Material Processing Technology, Vol. 103, No. 1, 2000, pp. 65-73.

[4] Heo, Y. M., Wang, S. H., et al. “The effect of the drawbead dimensions on the weld-line movements in the deep drawing of tailor-welded blanks”, Journal of Material Processing Technology, Vol. 113, No. 1-3, 2001, pp. 686–691.

[5] He, S., Wu, X., Hu, S. J., “Formability enhancement for tailor-welded blanks using blank holding force control”, Journal of Manufacturing Science and Engineering: Transaction of ASME, Vol. 125, No. 3, 2003, pp. 461–467.

[6] Kinsey, B. L., Cao, J., “An Analytical Model for Tailor Welded Blank Forming”, Journal of Manufacturing Science and Engineering: Transaction of ASME, Vol. 125, No. 2, 2003, pp. 344–351.

[7] Bravar, M. N., Kinsey, B. L., “Analytical determination of initial weld line position for tailor welded blank forming”, North American Manufacturing Research Institution of SME, Vol. 32, No. 1, 2004, pp. 597–604.

[8] Ku, T. W., Kang B. S., Park H. J., “Tailored blank design and prediction of weld line movement using the backward tracing scheme of finite element method”, International Journal of Advanced Manufacturing Technology, Vol. 25, No. 1, 2005, pp. 17–25.

[9] Chan, L. C., Cheng, C. H., Chan, S. M., Lee, T. C., Chow, C. L., “Formability Analysis of Tailor-Welded Blanks of Different Thickness Ratios”, Journal of Manufacturing Science and Engineering: Transaction of ASME, Vol. 127, No. 4, 2005, pp. 743–751.

[10] Padmanabhan, R., Baptista, A. J., Oliveira, M. C., Menezes, L. F., “Effect of anisotropy on the deep-drawing of mild steel and dual-phase steel tailor-welded blanks”, Journal of Material Processing Technology, Vol. 184, No. 1-3, 2007, pp. 288–293.

[11] Tang, B. T., Zhao, Z., Yu, S., Chen, J., Ruan, X. Y., “One-step FEM based control of welding line movement for tailor-welded blanks forming”, Journal of Material Processing Technology, Vol. 187–188, 12 June 2007, pp. 383–386.

[12] Wang, L. J., Wang, G. D., Liu, X. H., Wu, M. T., “Numerical Study on Welding Line Behavior of Deep Drawing TWB Process”, Journal of Iron and Steel Research International, Vol. 14, No. 5, 2007, pp. 36-38.

[13] Padmanabhan, R., Oliveira, M. C., Menezes L. F., Deep drawing of aluminium–steel tailor-welded blank, Materials and Design, Vol. 29, No. 1, 2008, pp. 154–160.

 

 

 

[14] Padmanabhan, R., Oliveira, M. C., Laurent, H., Alves, J. L., Menezes, L. F., “Study on springback in deep drawn tailor welded blanks”, International Journal of Material Forming, Vol. 2, Aug. 2009, pp. 829-832.

[15] Abbasi, M., Bagheri, B., Ketabchi, M., Haghshenas, D. F., “Application of response surface methodology to drive GTN model parameters and determine the FLD of tailor welded blank”, Computational Materials Science, Vol. 53, No. 1,  2012, pp. 368-376.

[16] Abbasi, M., Ketabchi, M., Labudde, T., Prahl, U., Bleck, W., “New attempt to wrinkling behavior analysis of tailor welded blanks during the deep drawing process”, Materials and Design, Vol. 40, Sep. 2012, pp. 407-414.

[17] Rojek, J., Hyrcza-Michalska, M., Bokota, A., Piekarska, W., “Determination of mechanical properties of the weld zone in tailor-welded blanks”, Archives of Civil and Mechanical Engineering, Vol. 12, No. 2, 2012, pp. 156-162.

[18] Fazli, A., “Optimum tailor-welded blank design using deformation path length of boundary nodes”, International Journal of Automotive Engineering, Vol. 3, No. 2, 2013, pp. 435-445.

[19] Mohebbi, M. S., Akbarzadeh, A., “Prediction of formability of tailor welded blanks by modification of MK model”, International Journal of Mechanical Sciences, Vol. 61, No. 1, 2012, pp. 44-51.

[20] Safdarian Korouyeh, R., Moslemi Naeini, H., Torkamany, M. J., Liaghat, G. H., “Experimental and theoretical investigation of thickness ratio effect on the formability of tailor welded blank”, Optics & Laser Technology, Vol.51, Oct. 2013, pp. 24-31.

 [21] Masumi, H., Masoumi, A., Hashemi, R., Mahdavinejad, R., “A Novel Approach to the Determination of Forming Limit Diagrams for Tailor-Welded Blanks”, Journal of Materials Engineering and Performance, Vol. 22, No. 11, 2013, pp. 3210-3221.

[22] Swift, H. W., “Plastic instability under plane stress”, Journal of the Mechanics and Physics of Solids, Vol. 1, No. 1, 1952, pp. 1-18.