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TECHNICAL PAPERS

Experimental and Theoretical Analysis on Formability of Aluminum Tailor-Welded Blanks

[+] Author and Article Information
M. Jie, C. L. Chow

Department of Mechanical Engineering, The University of Michigan-Dearborn, Dearborn, MI

C. H. Cheng, C. Y. Tang

Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Hong Kong, China

L. C. Chan1

Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Hong Kong, Chinamflcchan@inet.polyu.edu.hk

1

Corresponding author.

J. Eng. Mater. Technol 129(1), 151-158 (Jun 21, 2006) (8 pages) doi:10.1115/1.2400274 History: Received December 02, 2005; Revised June 21, 2006

This paper presents an investigation on forming limits of tailor-welded blanks (TWBs) made of 5754-O aluminum sheets using both experimental and numerical approaches. TWBs may be composed of two or more welded flat metal sheets of different thicknesses, shapes, or mechanical properties. Due to the existence of weldment and the individual configurations of base blanks, TWBs should be considered as heterogeneous in its structure. The mechanical properties of those base metals and weld metal required for the simulation were measured individually. With the aid of the acquired data, finite element simulations for analyzing the forming process of TWBs were carried out using a general purpose finite element package, LS-DYNA. A localized necking criterion based on the vertex theory was employed to predict forming limit strains and failure locations of the aluminum TWBs. The theoretical predictions were satisfactorily validated with those obtained from the experiments.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

σ̃−ϵ̃ curves of: (1) 1.3mm base metal; (2) 1.0mm base metal; and (3) weldment in TWB

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Figure 2

5754-O aluminum TWBs with different widths

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Figure 3

Schematic diagram of forming test

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Figure 4

FE modeling for forming simulation: (a) tooling setup; (b) coarse FE mesh of the TWB (width: 25mm); and (c) fine FE mesh of the TWB (width: 25mm)

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Figure 5

5754-O aluminum TWBs after forming test

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Figure 6

Simulation results of TWB forming (major strain distributions): (a) TWB with a width of 101mm; (b) TWB with a width of 75mm; (c) TWB with a width of 51mm; and (d) TWB with a width of 25mm

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Figure 7

Sample of failure initiated at weldment

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Figure 8

Forming limits of 5754-O aluminum TWBs (1.0mm∕1.3mm)

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Figure 9

Forming limits of 5754-O aluminum TWBs and its base metals

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Figure 10

Forming limit strains of 5754-O aluminum TWBs

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Figure 11

Measurement of major and minor strains of deformed TWB along the centerline perpendicular to weldment

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Figure 12

Comparison of strain distributions on TWBs between the simulation and experimental results: (a) TWB with a width of 101mm; and (b) TWB with a width of 25mm

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