TWB front side rails have been discussed, and the optimal gauge for tailored blanks was determined based on stress distribution from static analysis using self-weight load .
[31.] Shi, Y, Zhu, P., Shen, L., and Lin, Z., "Lightweight Design of Automotive Front Side Rails with TWB Concept," Thin-Walled Structures 45:8-14, 2007.
In order to simplify the manufacturing process, the usage of tailor-welded blanks (TWB) represents an optimal solution due to the fact that we can use one single welded part instead of using several distinct parts which would require a large number of processing stages during manufacturing (Geiger et al., 2008).
Therefore no modifications of the forming system are needed when switching from deep-drawing monoblock blanks to deep-drawing the TWB, but the weight of the TWB is significantly lower than that of a monoblock blank made entirely of 1.5 mm steel sheet.
The results presented in this paper have shown that at the deep drawing of a tailor-welded blank, the main parameters concerning formability (specific strains and thinning) and energy balance are very close to those specific for a monoblock part with the same thickness as the TWB.
A very important concern in TWBs is weld line movement.
The obtained results for sqare shape were analysed to realise the behaviour of the TWBs in the deep drawing process.
This process modification was successful at reducing the weld line movement and delaying tearing failure along the weld line compared to the case where a uniform binder force was applied to the TWB.
To determine the mechanical properties of the welding line, from the original TWB, a 4 mm wide stripe which includes the welding line, has been removed using EDM wire cutting (Fig.
The deep-drawing process simulation is accomplished in two phases: (i) the blank holder is moved to apply a predetermined holding force on the TWB; (ii) the punch is moved to a predetermined depth;