Aluminum Alloy Tailor Welded
Tailored blanking is a
relatively new method of producing automotive structural components. It
involves seam welding together two or more separate sheet metal pieces
to form a composite blank. This approach allows the designer to combine
different gauges, and even different alloys in the same blank. The
formed sheet metal part can than be optimized for weight and function,
while reducing waste material, assembly time and even design effort.
Current applications of tailored blanks allow designers to amalgamate
stamped and welded assemblies of numerous separate pieces into one
part. Applications include any part or assembly that require different
properties in different locations.
finite element model meshes
Formability data is collected
from limiting dome height tests and deep drawing tests. Various
combinations of sample geometry and weldline placement produce
different strain paths. Strains measured at sample failure then define
the forming limits for that particular strain path. This formability
data is then assembled to construct a forming limit diagram (FLD).
(necking) in a stretch formed TWB
Finite Element Modeling
Finite element modeling of the
TWB forming process makes it possible to predict the formability of a
part without first building a prototype as shown below. Modeling the
strain distribution in the part, especially in the material adjacent to
the weld line is critical. Finite element modeling of a part can speed
up the development of TWB in industrial applications.
FE model (showing
major strain contours) and experimentally drawn cup
Diagram: Strain Comparison
With formability knowledge of
TWB’s and accurate finite element models, more aggressive
weld line placements can be pursued. This leads to more flexibility for
designers and better optimization of parts.
Medium Scale TWB
Large Scale TWB
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