Abstract
The feasible cold forming procedure to massively manufacture ultra-high strength steel (UHSS) light-weighting profiles so far in industrial fields consists of roll forming, welding, cutting and bending. To reveal the role the high-frequency induction weld (HFIW) line plays in the subsequent plastic forming, a serials of deliberately designed collapse tests of the shell structures taken from M1700 roof rail pillar with a wall-thickness of 2 mm and triangle cross-section were conducted. Real geometries and inhomogeneous material properties of the weld seam and heat-affected zone (HAZ), together with the residual tensile stresses within the weld seam after HFIW, were fully considered in the numerical simulation. The Brozoo's modified CL damage model and Oyane damage model were employed and compared. The results show that the deformation resistance of the shell structures is modified by the material accumulation around the HFIW seams during the collapse tests. The cracks mainly occur within the critical HAZ outside the tube and the temper softening zone inside the tube under the action of softening effect in the HAZ of M1700 steel. The residual tensile stresses increase the crack probability of weld seams. The predicting accuracy of fracture location of the Oyane damage model is higher than that of the Brozoo's modified CL damage model.
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