Tailored Blank Weld Bead Width Design for Press-Forming Deformation
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Solution Overview
Problem
In tailored blanks, press forming can cause movement and deformation of weld beads, leading to changes in their strength and width, which are often overlooked in design calculations, resulting in overestimations of strength properties and deviations from intended final product characteristics.
Innovation Solution
A method is developed to design and manufacture tailored blanks by acquiring analysis model data, performing press-forming analysis, and adjusting the weld bead width design based on calculated deformation, ensuring the weld bead width in the press-formed product aligns closer to a target value, using bead-width design data to control heat input and filler metal supply during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press forming is performed on tailored blanks, then the final product shape is achieved, but the weld bead width changes and strength properties deviate from design calculations
Solution Approach 1:
The patent applies preliminary action by performing press-forming analysis before actual welding to predict weld bead deformation. The analysis model calculates how the weld bead will deform during press forming, and this prediction is used to adjust the weld bead width design values in advance. By compensating for expected deformation through preliminary calculation, the final weld bead width after press forming matches the target value, resolving the contradiction between achieving final product shape and maintaining weld bead precision.
2Device complexity
If weld bead deformation during press forming is ignored in design calculations, then calculation complexity is reduced, but strength properties are overestimated and deviate from actual results
Solution Approach 1:
The patent incorporates weld bead deformation into the preliminary press-forming analysis stage. The analysis model includes weld bead elements that calculate deformation during press forming, and these results are used to adjust design values before welding. This preliminary consideration of deformation maintains calculation feasibility while significantly improving strength property prediction accuracy, resolving the contradiction between calculation simplicity and prediction accuracy.
3Loss of time
If the weld bead is not included in press-forming analysis, then analysis processing time is reduced, but the final product strength properties diverge from analysis results
Solution Approach 1:
The patent performs weld bead deformation analysis as part of the preliminary press-forming analysis process. The analysis model includes weld bead elements that are calculated during the press-forming simulation, and the results are used to adjust weld bead width design values before actual manufacturing. This preliminary inclusion of weld bead analysis improves prediction reliability while keeping processing time acceptable through efficient numerical methods and targeted analysis scope.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures that the weld bead width in the press-formed product is accurately controlled, reducing deviations in strength properties and improving the consistency of the final product's performance by accounting for press-forming-induced changes, thereby enhancing the reliability of design predictions.
Implementation Method 1
press forming may not only cause movement of the position of the weld bead on the formed surface, but also cause a change in the weld bead width
Implementation Method 2
Joining of sub-sheets into a tailored blank is performed, for example, by welding such as laser welding or plasma welding
Implementation Method 3
welding such as laser welding or plasma welding
Implementation Method 4
welding such as laser welding or plasma welding
Data Source
AI summary
A method of designing the width of the weld bead in a tailored blank includes: a model acquisition step for acquiring analysis model data containing elements for the first sheet, elements for the second sheet, and elements for the weld bead; a press-forming analysis step for performing press-forming analysis using the analysis model data to calculate deformation of the various elements when the tailored blank is press formed; and a bead-width designing step for deciding on a design value of the width of the weld bead for each of positions along the longitudinal direction of the weld bead in the tailored blank prior to press forming based on a press-forming-induced change in the width relating to the elements for the weld bead obtained through calculation, to generate bead-width design data indicating the relationship between a position along the longitudinal direction of the weld bead and the design value of the width of the weld bead.