3 - Mechanics-based modeling of tailor welded blank forming

Abstract

Tailor welded blanks (TWBs) offer several notable benefits including decreased component weight, reduced manufacturing costs, increased environmental friendliness and improved dimensional accuracy. In order to take full advantage of these benefits, designers must be able to predict the reduced formability of TWBs and the unique attributes related to TWB forming early in the design process. In this chapter, analytical models to predict the limiting thickness ratio of the TWB combination and the forming behavior of TWBs will be presented. In these studies, comparisons with numerical simulations and experimental results will be used to validate the accuracy of these models. Such analytical models provide designers with valuable tools to determine material and process parameters for the application, such as the location of steps on the die surface to accommodate the weld displacement, the non-uniform binder force ratio to prevent weld line movement and the potential forming height for a TWB forming process.