New method of producing tailored blanks with constant thickness

Andrzej Rosochowski, Lech Olejnik

Research output: Contribution to journalConference Contribution

1 Citation (Scopus)

Abstract

The concept of weight-saving in automotive manufacture by using tailored blanks is well established. The methods used to produce extra strength in particular areas of the blank can be based either on increasing material thickness in those areas or keeping the thickness constant but varying the material properties. Typically the first option is used by welding blank patches of different thickness. From the view point of forming blanks into sheet metal products uniform thickness is less problematic and it can be achieved by welding different materials of the same thickness or localised heat treatment. However, these approaches have major limitations: welding introduces discontinuity in material structure and properties while selective heat treatment is difficult to control. A new, original method presented here is based on a local shear deformation of the blank material. The particular process used is incremental equal channel angular pressing. The proposed approach is simulated using finite element modelling and then experimentally verified by producing a constant thickness pure aluminium strip with varying hardness. A discussion of different variants of this approach indicates its potential.

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Welding
Heat treatment
Equal channel angular pressing
Sheet metal
Shear deformation
Materials properties
Hardness
Aluminum

Keywords

  • tailored blanks
  • sheet metal
  • Incremental forming
  • shear deformation

Cite this

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title = "New method of producing tailored blanks with constant thickness",
abstract = "The concept of weight-saving in automotive manufacture by using tailored blanks is well established. The methods used to produce extra strength in particular areas of the blank can be based either on increasing material thickness in those areas or keeping the thickness constant but varying the material properties. Typically the first option is used by welding blank patches of different thickness. From the view point of forming blanks into sheet metal products uniform thickness is less problematic and it can be achieved by welding different materials of the same thickness or localised heat treatment. However, these approaches have major limitations: welding introduces discontinuity in material structure and properties while selective heat treatment is difficult to control. A new, original method presented here is based on a local shear deformation of the blank material. The particular process used is incremental equal channel angular pressing. The proposed approach is simulated using finite element modelling and then experimentally verified by producing a constant thickness pure aluminium strip with varying hardness. A discussion of different variants of this approach indicates its potential.",
keywords = "tailored blanks, sheet metal, Incremental forming, shear deformation",
author = "Andrzej Rosochowski and Lech Olejnik",
year = "2017",
month = "11",
day = "15",
doi = "10.1016/j.proeng.2017.10.909",
language = "English",
volume = "207",
pages = "1433--1438",
journal = "Procedia Engineering",
issn = "1877-7058",

}

New method of producing tailored blanks with constant thickness. / Rosochowski, Andrzej; Olejnik, Lech.

In: Procedia Engineering, Vol. 207, 15.11.2017, p. 1433-1438.

Research output: Contribution to journalConference Contribution

TY - JOUR

T1 - New method of producing tailored blanks with constant thickness

AU - Rosochowski, Andrzej

AU - Olejnik, Lech

PY - 2017/11/15

Y1 - 2017/11/15

N2 - The concept of weight-saving in automotive manufacture by using tailored blanks is well established. The methods used to produce extra strength in particular areas of the blank can be based either on increasing material thickness in those areas or keeping the thickness constant but varying the material properties. Typically the first option is used by welding blank patches of different thickness. From the view point of forming blanks into sheet metal products uniform thickness is less problematic and it can be achieved by welding different materials of the same thickness or localised heat treatment. However, these approaches have major limitations: welding introduces discontinuity in material structure and properties while selective heat treatment is difficult to control. A new, original method presented here is based on a local shear deformation of the blank material. The particular process used is incremental equal channel angular pressing. The proposed approach is simulated using finite element modelling and then experimentally verified by producing a constant thickness pure aluminium strip with varying hardness. A discussion of different variants of this approach indicates its potential.

AB - The concept of weight-saving in automotive manufacture by using tailored blanks is well established. The methods used to produce extra strength in particular areas of the blank can be based either on increasing material thickness in those areas or keeping the thickness constant but varying the material properties. Typically the first option is used by welding blank patches of different thickness. From the view point of forming blanks into sheet metal products uniform thickness is less problematic and it can be achieved by welding different materials of the same thickness or localised heat treatment. However, these approaches have major limitations: welding introduces discontinuity in material structure and properties while selective heat treatment is difficult to control. A new, original method presented here is based on a local shear deformation of the blank material. The particular process used is incremental equal channel angular pressing. The proposed approach is simulated using finite element modelling and then experimentally verified by producing a constant thickness pure aluminium strip with varying hardness. A discussion of different variants of this approach indicates its potential.

KW - tailored blanks

KW - sheet metal

KW - Incremental forming

KW - shear deformation

U2 - 10.1016/j.proeng.2017.10.909

DO - 10.1016/j.proeng.2017.10.909

M3 - Conference Contribution

VL - 207

SP - 1433

EP - 1438

JO - Procedia Engineering

T2 - Procedia Engineering

JF - Procedia Engineering

SN - 1877-7058

ER -