Experimental and Numerical Investigations of Constraint Effect on Deformation Behavior of Tailor-Welded Blanks

Abstract

Tailor-welded blanks (TWBs) have been considered as a productive sheet forming method in automotive industries. However, formability of TWBs is reduced due to different properties or thicknesses of the blanks and is a challenge for manufacturing designers. The plastic capacity of TWBs is decreased even when the material and thickness are the same. The constraint effect of the laser weld (including weld and heat-affected zone) material in the forming process of similar TWBs is a key problem to be solved in the research, development and application of thin-sheet TWBs. In this paper, uniaxial tensile tests with full-field strain measurement by digital image correlation and Erichsen tests are performed to investigate the constraint effect on deformation behavior and explore the mechanism of decreasing formability of similar TWBs. In addition, finite element models are conducted under ABAQUS code to further reveal the phenomenal behavior of the constraint effect. The results of the base material and welded blanks are compared for characterizing the differences. Furthermore, in order to better understand this mechanism, theoretical and numerical investigations are employed and compared to interpret the constraint effect of laser weld on the deformation behavior of TWBs. An index is proposed to quantify the constraint effect. Results show that the constraint effect of laser weld appears in both stretch forming and drawing of TWBs. Strain paths are approaching the plane strain condition as compared to the monolithic blank due to the constraint effect. Constraint effect is a major factor affecting the formability of TWBs when the failure occurs away from the weld seam.