Abstract
Recently, tailored blank sheets have been widely and frequently used in automotive parts such as door inner and body side inner parts in order to reduce the weight of a car body and the number of parts. The control of the gap between batting blank sheets with different thicknesses below 0.1mm and the appropriate choice of the material for producing a tailored blank sheet are considered as main subjects in the development of new stamping parts using laser-welded tailored blank sheets. Therefore, in this study, we investigated the mechanism of gap control in a batting process and developed a dynamic explicit finite element method (FEM) for predicting the gap in a batting process in a testing machine. We also investigated a contact algorithm and friction to increase computation accuracy. The accuracy of the prediction of the gap by the proposed FEM has been verified with experimental measurement data for simple rectangle steel sheets and blanks of body side inner parts. The effects of the design variables of a batting machine on the gap were also investigated using the proposed FEM, and an equation for predicting gap was proposed.
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