Numerical investigation on forming behavior of friction stir tailor welded blanks (FSTWBs) during single-point incremental forming (SPIF) process

Abstract

Tailor welded blank (TWB) is a product which is developed by joining two or more than two materials having same/different thickness and/or properties before any forming process. The method to join the materials can be any of the conventional or advanced methods. TWB offers advantages like overall weight and cost reduction in a product. Despite of such advantages, the application of TWBs is partially resisted by the disadvantages associated with it like formability reduction and weld line movement during the forming operations. A lot of effort has been done in order to overcome the mentioned limitations of the TWBs. However, for homogeneous blank, single-point incremental forming (SPIF) results in better formability so in present work, the attempt has been made to study the forming behavior of TWB during the SPIF process. In this work, the effect of TWB material parameters like yield strength ratio, thickness ratio, strength coefficient ratio and strain index ratio of the parent materials has been investigated on the weld line movement and % thinning of the blank through finite element analysis. In order to perform the numerical analysis, ABAQUS/Explicit was used. Using SPIF, round cup geometry is formed from a flat TWB and effect of different initial positions of tool is investigated. It has been found that when the forming process is started from the weld and tool is travelled toward strong material of the blank, it leads to the minimum thinning, weld line shift and plastic equivalent strain (PEEQ).

Experimental Research on the Behaviour of Metal Active Gas Tailor Welded Blanks during Single Point Incremental Forming Process

“…Figure 12 presents the specimens immediately after the crack occurred. Marathe also concluded, on the basis of a finite element simulation, that the maximum springback value occurs in the case of TWBs compared to unwelded blanks, especially in the case of strong materials [41].…”

“…A numerical investigation, using the finite element method (FEM), on the behaviour of FSTWBs during SPIF process is presented by Marathe and Raval [41]. They used three types of materials: a "strong" material, a "weak" material and another material for the welding bead.…”

A numerical approach for the modelling of forming limits in hot incremental forming of AZ31 magnesium alloy

“…8). This is one of the reasons why some researchers have used PEEQ as a sort of "formability index" as also mentioned by Shalin et al [21]. An interesting observation can be made looking at the thickness distribution: different from what occurs in conventional SPIF (i.e., at room temperature), in warm conditions the part area characterized by minimum thickness is not close to the top surface of the sheet but is distributed quite evenly along the wall.…”

Fracture Modelling of a Cracked Pressurized Cylindrical Structure by Using Extended Iso-Geometric Analysis (X-IGA)

“…IGA has been employed in a variety of engineering fields, including the mechanics of vibration [22,23], fluid mechanics [24], electromagnetic problems [25], the medical field [26], and digital image correlation [27]. The issues addressed are diverse, including nonlinear mechanics [28], shell analysis [29][30][31][32][33][34], contact problems [35,36], fluidstructure interactions [24], the optimization of structural design [37], buckling failure [38], and crack problem analysis [39]. From this research, IGA has indicated the effectiveness of its results and it can sweep the world of numerical computation.…”