On modeling of the weld line in finite element analyses of tailor-welded blank forming operations

Effect of anisotropy on the deep-drawing of mild steel and dual-phase steel tailor-welded blanks

“…Tailor-welded blanks thus produced with dis-similar and uniform or non-uniform thickness materials can be subjected to deformation to produce automobile components, such as body side panels, motor compartment rails, center pillar inner panels, wheelhouse/shock tower panels [1][2][3][4] and other market areas [5]. The formability of tailor-welded blanks is significantly affected by the location and orientation of the weldline [6][7][8]. The strength and thickness mismatch between the monolithic sheet materials produces complex stress state in the tailor-welded blank during deep-drawing.…”

“…In addition, the formability and failure patterns of tailor-welded blanks can be accurately predicted with appropriate draw restraining forces and material properties. Application of finite element methods to deep-drawing analysis, with the aim to better understand the forming processes, enables precise designing of tailor-welded sheet metal parts, the tools and the forming processes [6][7][8]10]. Many studies have been undertaken to determine the formability of tailor-welded blanks using standard tests, such as free bend test, stretch bend test, Limit Dome Height test, both experimentally and through simulation [10,11].…”

Prediction of Tensile and Deep Drawing Behaviour of Aluminium Tailor-Welded Blanks

“…Each parameter has three levels (1, 2 and 3). The levels of parameters are chosen in such a way that the range covers practically all the combinations in typical experiments and industrial parts (Raymond et al, 2004;Saunders & Wagoner, 1996;Stasik & Wagoner 1998). In case of tensile test simulation the weld orientations that are significant i.e.…”

Study of hydroformed tailor-welded tubular parts with dissimilar thickness

“…This type of blanks has several advantages, namely low cost (compared to welding operations carried out on final products), the reduction in part weight and flexibility in mass production. Specifically for the laser-welding process it is possible to manufacture superior parts, since high strength, hardness of the welded zone and a narrow weld bead can be obtained [15][16][17]. Related to numerical simulation of welded blanks, it is worth mention the work of Raymond et al [17], using nodal rigid bodies to join thin and thick parts.…”

“…Specifically for the laser-welding process it is possible to manufacture superior parts, since high strength, hardness of the welded zone and a narrow weld bead can be obtained [15][16][17]. Related to numerical simulation of welded blanks, it is worth mention the work of Raymond et al [17], using nodal rigid bodies to join thin and thick parts. Solid elements for the weld-line, along with shell elements (4-node quadrilateral) for the base material, were used.…”