Tailor-welded blanks of interstitial free steel are commonly used in complex automotive skin panels. The presence of weld zone, difference in thickness and high anisotropic behaviour affect forming behaviour of tailor-welded blanks significantly. Therefore, incorporation of anisotropy of the sheets and properties of the weld zone in finite element simulations is very important for accurate prediction of springback in bending of tailor-welded blanks. In this study, experimental and finite element simulations of V-bending were carried out on tailor-welded blanks of three thickness combinations, prepared by Nd-YAG laser welding of interstitial free steel sheets of thicknesses 0.8, 1.2 and 1.5 mm. The orientation of the weld line in longitudinally welded blanks was kept at 0°, 45°and 90°with respect to the rolling direction to study the effects of anisotropy on springback in V-bending. The tensile properties of the weld zone in different thickness combinations were determined and incorporated in finite element simulations for prediction of springback. It was observed that springback results were mainly governed by the springback behaviour of the thicker sheet in a particular thickness combination. Weld zone properties affect the springback of tailor-welded blanks more significantly than the anisotropy of the sheets. Accuracy of predicted values of springback in simulations increased when the properties of the weld zone were incorporated in the material model.
An analytical model for the prediction of springback in bending of longitudinally welded tailor-welded blanks of different thickness is presented in this paper. The effect of strain hardening, anisotropy and weld zone has been incorporated in the analytical model. Power law of strain hardening and Hill's anisotropic yield criterion have been used in the development of the analytical model for prediction of springback in tailor-welded blanks. The predicted values of springback are validated with experiments on V-bending of laser-welded blanks of Extra Deep Drawing quality steel sheets. Longitudinally welded specimens of three different thickness combinations with weld line oriented at 0 , 45 and 90 to the rolling direction are tested to investigate the effect of anisotropy. The springback values predicted by the analytical model incorporating the weld properties are found to be in good agreement with the experimental results in all of the cases. The springback has been found to be maximum when the weld line is oriented at 45 to the rolling direction.
The present work deals with the development of an analytical model incorporating the effects of anisotropy and strain hardening to predict the springback in V-bending of 2-ply sheet metal using a punch profile radius of 15mm and included bend angle of 90°. The 2-ply sheet composed of layers of AA1050 and SS430 is characterized for its tensile properties to be used in analytical and numerical models for prediction of springback. To study the effect of each layer during bending operation, two possible cases of sheet placements during bending and springback are studied i.e. in the first case, the inner layer is of AA1050 while the SS430 layer is the outer layer whereas in the second case it is opposite. In all the cases of springback experiments when the outer layer is of SS430, the springback values are higher than the values obtained with the specimens when the inner layer is of SS430. This could be attributed to the higher tensile strength of the SS layer and the higher bending radius experienced by it. The springback behaviours are also analyzed by simulations using Hill's anisotropic yield criterion in ABAQUS software. The springback results obtained by simulations and analytical models are in good agreement with the results obtained by experiments.
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