Comparison of Analytical Model to Experimental and Numerical Simulations Results for Tailor Welded Blank Forming

[+] Author and Article Information
Matt Bravar

Department of Mechanical Engineering,  University of New Hampshire, 33 College Road, Durham, NH 03824

Neil Krishnan

Mechanical Engineering Department,  Northwestern University, 2145 Sheridan Road, Evanston, IL 60208

Brad Kinsey1

Department of Mechanical Engineering,  University of New Hampshire, 33 College Road, Durham, NH 03824bkinsey@unh.edu


Corresponding author.

J. Manuf. Sci. Eng 129(1), 211-215 (Aug 02, 2006) (5 pages) doi:10.1115/1.2401628 History: Received June 22, 2005; Revised August 02, 2006

Tailor welded blanks (TWBs) offer several notable benefits including decreased part weight, reduced manufacturing costs, and improved dimensional consistency. However the reduced formability and other characteristics of the forming process associated with TWBs has hindered the industrial utilization of this blank type for all possible applications. One concern with TWB forming is that weld line movement occurs, which alters the final location of the various materials in the TWB combination. In this technical brief, an analytical model to predict the initial weld line placement necessary to satisfy the desired, final weld line location and strain at the weld line is used. Results from this model are compared to an experimental, symmetric steel TWB case and a 3D numerical simulation, nonsymmetric aluminum TWB case. This analytical model is an extension of one previously presented, but eliminates a plane strain assumption that is unrealistic for most sheet metal forming applications. Good agreement between the analytical model, experimental, and numerical simulation results with respect to initial weld line location was obtained for both cases. Results for the model with a plane strain assumption are also provided, demonstrating the importance of eliminating this assumption.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 4

Formed symmetric part from Krishnan and Cao (14)

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Figure 5

Strain in the 2-direction for various cases

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Figure 6

Nonsymmetric, aluminum TWB case: (a) FEA results for percentage of thickness reduction and (b) formed part

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Figure 1

2D cross-sectional view showing tooling and variable locations

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Figure 2

Example of 2D cross-sectional location on a 3D part

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Figure 3

2D cross-section locations



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