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tailor-welded blanks
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Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005129
EISBN: 978-1-62708-186-3
... Abstract This article briefly reviews the forming of steel tailor-welded blanks (TWB) with a discussion on the effects of welding on forming. It presents the parameters that are monitored to control the stamping operation for tailor-welded blanks. The article discusses weld factors...
Abstract
This article briefly reviews the forming of steel tailor-welded blanks (TWB) with a discussion on the effects of welding on forming. It presents the parameters that are monitored to control the stamping operation for tailor-welded blanks. The article discusses weld factors such as the orientation of weld relative to metal movement in dies, the formability of TWB materials, die and press considerations, and specific factors for the drawing, stretching, and bending of steel tailor-welded blanks.
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Published: 30 November 2018
Fig. 32 Bridge-style friction stir welding system for tailor-welded blanks. Courtesy of TWB Company, LLC. Source: Ref 40
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Image
Published: 01 January 2006
Fig. 2 Laser welding using filler wire to make tailor-welded blanks and the resulting hardness distribution
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Published: 30 November 2018
Fig. 5 (a) Cross section of aluminum tailor-welded blank from two-sided laser welding. (b) The use of two diode lasers not only increases the process speed but also optimizes weld seam geometry and avoids defects. Courtesy of Thyssen Krupp
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Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005100
EISBN: 978-1-62708-186-3
... process-related developments, namely, superplastic forming of aluminum, forming of tailor-welded blanks, rubber-pad forming, and high-velocity metal forming. The article explains cost-effective approaches of evaluating tooling designs prior to the manufacture of expensive steel dies and dieless forming...
Abstract
Sheet forming comprises deformation processes in which a metal blank is shaped by tools or dies, primarily under the action of tensile stresses. This article discusses the classification of sheet-forming processes for obtaining desired dimensional features. It describes different process-related developments, namely, superplastic forming of aluminum, forming of tailor-welded blanks, rubber-pad forming, and high-velocity metal forming. The article explains cost-effective approaches of evaluating tooling designs prior to the manufacture of expensive steel dies and dieless forming techniques such as thermal forming and peen forming. It provides information on the application of advanced high-strength steels, magnesium alloys, and various ultrafine-grain materials for superplastic sheet forming. The article concludes with information on the development and application of simulation, design, and control of sheet-forming processes.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005638
EISBN: 978-1-62708-174-0
... real-time or in-process monitoring, which is done with optical, acoustic, and/or charged-particle sensors. It highlights the advantages, applications, and selection criteria of weld monitoring system and concludes with examples of laser weld monitoring in the production of tailor-welded blanks...
Abstract
This article reviews weld quality monitoring considerations for two automotive materials, steel and aluminum, with a focus on photosensor technology. It provides an overview of the process description, process parameters, and weld characteristics of laser welding. The article discusses real-time or in-process monitoring, which is done with optical, acoustic, and/or charged-particle sensors. It highlights the advantages, applications, and selection criteria of weld monitoring system and concludes with examples of laser weld monitoring in the production of tailor-welded blanks.
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Published: 01 January 2006
Fig. 7 Difficult forming areas with respect to the placement of welded joints on tailor-welded blanks
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Image
Published: 01 January 2006
Fig. 1 Welding geometries, welds, and heat-affected zones for the various welding techniques used to make tailor-welded blanks. (Values are typical for 1 mm, or 0.04 in., thick sheet and may vary depending on welding speed and power input.)
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Published: 01 January 2006
Fig. 6 Factors affecting deformation and failure during stretch flanging of tailor-welded blanks
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Published: 01 January 2006
Fig. 9 Trim line changes required to avoid edge splitting during trimming of formed tailor-welded blanks. It is important that the trim quality be maintained to prevent edge splitting.
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Published: 31 October 2011
Fig. 4 Sequence of operations required to produce “body-in-white” tailored blank automotive bodies using laser beam welding. (a) Arrangement and welding of divided-type body panels before forming. (b) Tailored blank obtained after structural components have been formed in a press. Source: Ref
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Image
Published: 01 January 1993
Fig. 2 Sequence of operations required to produce “body-in-white” tailored blank automotive bodies using laser-beam welding. (a) Arrangement and welding of divided-type body panels before forming. (b) Tailored blank obtained after structural components have been formed in a press. Source: Ref
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Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005141
EISBN: 978-1-62708-186-3
... be obtained with suitable lubrication. Forming Using Tailor-Welded Blanks A promising approach to reduce manufacturing costs, decrease vehicle weight, and improve the quality of automotive body components is through the use of tailor-welded blanks. This term refers to blanks where multiple sheets...
Abstract
This article discusses the general formability considerations of aluminum alloys. To conduct a complete analysis of a formed part, the required mechanical properties, as determined by several standard tests, must be considered. The article describes tension testing and other tests designed to simulate various production forming processes, including cup tests and bend tests, which help in determining these properties. It provides information on the equipment and tools, which are used in the forming of aluminum alloys. The article presents a list of lubricants that are most widely used in the forming. It also analyzes the various forming processes of aluminum alloys. The processes include blanking and piercing, bending, press-brake forming, contour roll forming, deep drawing, spinning, stretch forming, rubber-pad forming, warm forming, superplastic forming, explosive forming, electrohydraulic forming, electromagnetic forming, hydraulic forming, shot peening, and drop hammer forming.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005108
EISBN: 978-1-62708-186-3
... of Carbon Steels” in this Volume. Welded Blanks Tailor welded blanks are widely used in automobile, manufacturing (see the article “Forming of Steel Tailor-Welded Blanks” in this Volume.) Welded blanks are used when they have advantages over one-piece blanks, as in the following situations...
Abstract
This article discusses the production of blanks from low-carbon steel sheet and strip in dies in a mechanical or hydraulic press. It describes the cutting operations that are done by dies in presses to produce blanks. The applications of blanking methods are described with examples. The article reviews the characteristics of blanked edges and explains how to calculate the forces and the work involved in blanking. Factors affecting the processing of blanks are discussed. The article provides information on the selection of work metal form, the effect of work metal thickness on the selection of material for dies and related components, as well as the selection of die type and design. The article illustrates the construction and use of short-run dies and conventional dies. It concludes with information on the shaving and deburring methods for blanking.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005608
EISBN: 978-1-62708-174-0
... and/or coatings have been successfully mash seam welded. This development has created a whole new set of applications in tailored blank manufacturing, primarily for automotive use (see the ASM Handbook article “Forming of Steel Tailor-Welded Blanks” in Ref 1 ). Advantages and Limitations Advantages...
Abstract
This article describes the process applications, advantages, and limitations of resistance seam welding. The fundamentals of lap seam welding are also reviewed. The article details the types of seam welds, namely, lap seam welds and mash seam welds, and the processing equipment used for lap seam welding. The primary factors used to determine the selection of electrodes, including alloy type and wheel configuration, are reviewed. The article also describes weld quality and process control procedures.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005151
EISBN: 978-1-62708-186-3
... forming options, such as tailor-welded blanks, sheet hydroforming, and superplastic forming, before making a feasible and cost-effective decision. Sheet Metal Forming Processes Sheet metal forming is one of the most important manufacturing processes in the automotive industry. Several different...
Abstract
This article focuses on the technology breakthroughs that make forming simulation a routine work throughout the industry. It discusses many forms of the computer-aided engineering (CAE) methodology. The article describes several failure criteria to predict the failure of sheet metal. It explains the numerical procedure for sheet metal forming and reviews the important technical issues in CAE simulations. The article provides information on the applications and process of metal-forming simulation. It also reviews the capabilities of major systems that are popular among sheet metal forming users worldwide.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001365
EISBN: 978-1-62708-173-3
... a whole new set of applications in tailored blank manufacturing, primarily for automotive use ( Ref 2 ). Butt Seam Weld A joint in which two abutting edges are welded is classified as a butt seam joint ( Fig. 1c and 3 ). The thickness of the weld should be approximately the same, or slightly less...
Abstract
Resistance seam welding (RSEW) is a process in which the heat generated by resistance to the flow of electric current in the work metal is combined with pressure to produce a welded seam. This article discusses the various classes of the RSEW process, namely roll spot welding, reinforced roll spot welding, and leak-tight seam welding. It provides information on the applications of lap seam weld, mash seam weld, and butt seam weld. The article reviews the advantages and limitations of seam welding compared to resistance spot welding, projection welding, and laser welding. It describes the four basic types of resistance seam weld machines: circular, longitudinal, universal, and portable. The article concludes with a discussion on weld quality and process control for seam welding.
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006500
EISBN: 978-1-62708-207-5
... Abstract This article focuses on friction stir welding (FSW), where frictional heating and displacement of the plastic material occurs by a rapidly rotating tool traversing the weld joint. Much of the research activity early on pertained to issues related to understanding the process...
Abstract
This article focuses on friction stir welding (FSW), where frictional heating and displacement of the plastic material occurs by a rapidly rotating tool traversing the weld joint. Much of the research activity early on pertained to issues related to understanding the process, such as learning about material flow, heat generation, microstructure development, and many other fundamental issues. The article summarizes the results of the research, describing the aspects of how FSW actually accomplishes sound joints in metals without melting them. It discusses the FSW process variations and the practical aspects of heat generation. The article provides information on the effect of welding on material properties and typical alloys in FSW applications. The alloys include 6061 aluminum, 5083 aluminum, 2xxx aluminum, and 7xxx aluminum alloys. The article concludes with a discussion on FSW equipment.
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006502
EISBN: 978-1-62708-207-5
... method for the production of high-quality aluminum tailor-welded blanks, and excellent results have been achieved with two-sided simultaneous welding using two diode lasers ( Fig. 5 ). The use of two lasers not only increases the process speed but also offers qualitative advantages regarding both...
Abstract
Most welding lasers fall into the category of fiber, disc, or direct diode, all of which can be delivered by fiber optic. This article provides a comparison of the energy consumptions and efficiencies of laser beam welding (LBW) with other major welding processes. It discusses the two modes of laser welding: conduction-mode welding and deep-penetration mode welding. The article reviews the factors of process selection and procedure development for laser welding. The factors include power density, interaction time, laser beam power, laser beam diameter, laser beam spatial distribution, absorptivity, traverse speed, laser welding efficiency, and plasma suppression and shielding gas. The article concludes with a discussion on laser cutting, laser roll welding, and hybrid laser welding.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005110
EISBN: 978-1-62708-186-3
.... Without it, the process would lead to cold welding of the active elements (i.e., punch, die) to the blank and rapid wear and blunting of the die. Accordingly, precautions must be taken to ensure that the active elements are supplied with sufficient lubricant at every point of the cutting edge and forming...
Abstract
Fine-blanking is a hybrid metal forming process that combines the technologies of stamping and cold extrusion. This article describes the three principal design features of the fine blanking process: the vee-ring, clearance between punch and die, and counterforce imposed by the ejector. It discusses the advantages and disadvantages of edge blanking and materials. The article reviews the classification of fine-blanking dies such as the moving-punch system and the fixed-punch system, and provides information on the mechanical and hydraulic fine-blanking presses.
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