Maximum Bulge Height and Weld Line Displacement in Hydroforming of Tailor Welded Blanks

[+] Author and Article Information
Amit Kumar

Indian Institute of Technology Delhi, Department of Mechanical Engineering, Block II, Room No. 429, IIT Delhi, New Delhi, India 110016

Vijay Gautam

Delhi Technological University, Department of Mechanical Engineering, Bawana Road, New Delhi, India 110042

Digavalli Ravi Kumar

Indian Institute of Technology Delhi, Department of Mechanical Engineering, Block II, Room No. 357, IIT Delhi, New Delhi, India 110016

1Corresponding author.

ASME doi:10.1115/1.4038513 History: Received April 22, 2017; Revised November 07, 2017


Tailor-welded blanks (TWBs) have many advantages over traditional blanks for manufacturing automobile sheet metal components, such as significant flexibility in product design, higher structural stiffness and crash behavior. However, lower formability and weld line movement are some of the problems associated with forming of TWBs. Hydroforming is a potential technique to enhance formability. In this work, the effect of thickness ratio on maximum dome height and weld line movement in hydraulic bulging of laser welded Interstitial-Free (IF) steel blanks of different thickness combinations has been predicted using FE simulations. The results are also validated with hydraulic bulging experiments on TWBs. It has been found that with increase in thickness ratio, the maximum bulge height decreased and weld line displacement towards thicker side increased. These results have been used to relocate the weld line towards the thinner side in the initial blanks and achieve a more uniform bulge profile of the dome. The peak pressure to achieve maximum safe dome height and percentage thinning have also been found out. The results showed huge improvement in uniformity of bulge profile with little reduction in dome height.

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