Study of residual stresses in tailor rolled blanked Al5J32-T4 sheets

Several automotive parts such as door panels have been manufactured by using load-adapted blanks for crash optimization and weight minimization. Recently, Tailor Rolled Blanks (TRB) has been introduced to remove the disadvantages of a welding process which was used in joining panel components. TRB offers better structural design capabilities due to the seamless transitions on the panels with different thicknesses. In spite of the advantages of the process, TRB leaves internal stresses in the panel. This residual stresses lower the formability of Tailor Rolled Blanked (TRBed) parts and cause cracks near severe curvature during subsequent forming processes. In this research, the residual stresses of TRBed Al5J32-T4 sheets were studied by X-ray stress analysis, and also microstructure was observed along the rolling direction. In addition, heat treatment was done after TRB process in order to compare the residual stresses to that of the TRBed sheets before the heat treatment.

Prospects for Variable Gauge Rolling:Technology,Theory and Application

Variable gauge rolling （VGR） is a new technology to produce flat products with different thicknesses （FDT）, which could be used to replace conventional fiat products in order to save metals and reduce structure mass. The method of VGR was introduced for investigating new problems in rolling theory of VGR, and the new formulas for calculating parameters of VGR were proposed. Besides, some results of numerical simulation by finite elemen~ method were described. As an example, the products applications of FDT in bridge construction, ship building and auto manufacturing were presented. Finally, the prospects for VGR and FDT were discussed.

Recent Development on Theory and Application of Variable Gauge Rolling, a Review

Variable gauge rolling （VGR） is a new technology for producing the materials which have the advantage of lightweight due to optimized thickness according to load distribution. The new progresses in the theoretical research and application of VGR are reviewed in this paper. Two basic equations, VGR-f and VGR-s, were deduced. The former is a new differential equation of force equilibrium, and the latter is a new form of formula for the law of mass conservation. Both of them provide a new base for the development of VGR analysis. As the examples of VGR＇s application, tailor rolled blank （TRB） and longitudinal profile （LP） plate are introduced. Now TRBs are only produced in Germany and China, and have been used in the automotive manufacturing to play an important role in lightweight design. LP plates have been used in shipbuilding and bridge construction, and promised a bright prospect in reducing construction weight. In addition, new technologies and applications of VGR emerge constantly. Tailor welded strips and tailor rolled strips with variable thickness across the width can be used for progressive die and roll forming. The 3D profiled blank can be obtained by two-step rolling process. Tailor tubes witli the variable wail thickness are an efficient way to reduce the weight. The blank with tailored thickness and mechanical property is also under development. Above products based on the tailored ideas provide a new materials-warehouse for the designers to select so as to meet the needs of weight reducing and material saving.

Numerical Simulation and Vertical Motion Control of Rolls for Variable Gauge Rolling

The vertical motion control of the roll was studied in order to improve the accuracy in simulation of variable gauge rolling. The discretization was carried out in the transition zone of TRB according to the principle of volume invariance. Based on this assumption, the formula for time step of vertical motion of rolls was proposed and the time-displacement curve of the verti- cal motion of rolls was established. In the preliminary simulation, the time-displacement curve was used as an initial method to control the vertical motion of rolls. Based on the simulation result, the formula for vertical velocity of roll in variable gauge rolling was derived from the common rolling principle. According to the formula, reasonable vertical velocity of rolls in the subsequent simulation was determined. It can accurately control the motion of rolls along the vertical direction. The desired thickness and out- line profile of transition zone were acquired and the formula proved effective by the simulation. Further analysis shows that the di fference of thickness in the thick zone and the thin zone of TRB, length of the transition zone of TRB, radius of work rolls and rota- tion speed of rolls have a significant effect on the vertical velocity of rolls.

Study on Nonuniform Deformation of Tailor Rolled Blank During Uniaxial Tension

The deformation characteristics of tailor rolled blank （TRB） in the course of uniaxial tension were studied by means of analysis, test and simulation. The mechanical analytical model of TRB during uniaxial tension was set up, and the deformation formulae for the thinner side and for the thicker side were derived to quantify the deformation of TRB. On this basis, uniaxial tension tests on TRB and ordinary blanks （the thinner side and the thicker side of TRB） were conducted. Lagrange polynomial interpolation method was adopted to construct the stress-strain fields of unannealed and annealed TRBs for solving TRB material parameters, and then, uniaxial tension simulation on TRB was completed. Deformations and properties of unannealed TRB were compared with those of annealed TRB, and the thinner side and the thicker side were also compared. Finally, the research results were explained by metallurgical structure. The results show that nonuniform deformation happens in TRB during uniaxial tension, and the necking occurs on the thinner side. The agreement of analysis, test and simulation confirms the correctness of the analytical model and the deformation formulae. The findings of this paper can lay the foundation for the future study on TRB stamping formability and provide a way for TRB modeling.

Forming Limit and Thickness Transition Zone Movement for Tailor Rolled Blank during Drawing Process

The process of automobile lightweight can be promoted by the application of tailor rolled blank（TRB）in the automobile industry.Therefore,research on the formability of TRB is of good practical significance and application value because of the enormous potential of TRB in the aspect of automobile lightweight.Aiming at the present condition of lack of researches on the influence of characteristic parameters on TRB drawing process,the drawing formability of TRB was studied with a combination method of simulation and experiment by taking square box as the research object.Firstly,drawing simulation and experiment of TRB were carried out.Then,effects of thickness transition zone（TTZ）position and blank size on the drawing formability of TRB were analyzed.Forming limit and TTZ movement for TRB square box during the drawing process were respectively discussed,when transition zones of TRB were located at different positions and blanks were of different sizes.The results indicate that lubrication condition exerts greater influence on TRB forming limit in comparison with TTZ movement,and the smaller blank size and TTZ being located at the blank center or slightly offset to the thinner side are preferable for acquiring greater forming limit and smaller TTZ movement.

Transverse Bending Characteristics in U-channel Forming of Tailor Rolled Blank

Research on the formability of tailor rolled blank （TRB） is of good practical significance and application value because of the enormous potential of TRB in the aspect of automobile lightweight. However, the forming of TRB is problematic because of the varying properties; especially, springback is a main challenge. The transverse bending （bending axis is perpendicular to the rolling direction） of TRB U channel was studied through simulation and experiment. The forming characteristics of TRB U channel during transverse bending were analyzed. The mechanisms of forming defects, including bending springback and thickness transition zone （TTZ） movement, were revealed. On this basis, effects of blank geometric parameters on springbaek and TTZ movement were discussed. The results indicate that springback and TTZ movement happen during transverse bending of TRB U-channel. Nonuni form stress distribution is the most fundamental reason for the occurrence of springback of TRB during transverse bending. Annealing can eliminate nonuniform stress distribution, and thus diminish springbaek of TRB, especially springback on the thinner side. Therefore, springback of the whole TRB becomes more uniform. However, annealing can increase the TTZ movement. Blank thickness and TTZ position are the main factors affecting the formability of TRB U-channel during transverse bending.

Numerical Simulation and Experimental Investigation of Springback in U-Channel Forming of Tailor Rolled Blank

In order to grasp the springback rule of TRB ( tailor rolled blank ) parts after forming , the springback behavior of TRB was investigated by integrating such three means as theoretical research , numerical simulation and stamping experiments.Fundamental theories of springback were analyzed.The stamping and springback processes of annealed 1.2 / 2.0mm TRB , 1.2mm and 2.0mm plates for U-channel were simulated , and the simulation results were compared with the experiments.The results indicate that the springback of TRB falls in between those of the 1.2mm and 2.0mm plates.It is desirable for the TRB U-channel to have die clearance of 1.1times maximum blank thickness and friction coefficient of about 0.12 , and longer thickness transition zone is preferable.The simulation data demonstrate reasonably good agreement with the experiments.

Velocity Preset and Transitional Zone′s Shape Optimization for Tailor Rolled Blank

Tailor rolled blank （TRB） is a type of emerging material to produce lightweight vehicle parts. Transitional zoners shape is an important parameter for tailor rolled blank. It not only affects mold design and the local carrying capacity of the stamping parts, but also determines the maximum value and variation characteristics of rolling force. How to get the best transitional zone＇s shape is a key problem for production of tailor rolled blank. A double power function is put forward using for transitional curve, which is continuous and smooth at all connection points inde- pendent of its parameters, so the sudden change of mechanical parameters during rolling and forming process can be avoided. At the same time, the velocity formula and restriction for arbitrary transitional curve are derived to preset vertical velocity of the roller and judge whether the curve can be rolled successfully or not. Then, the finite element method （FEM） is used to verify the precision of velocity formula and study the mechanical characteristics of different curves. Finally, a method to obtain the optimal curve equation is put forward and verified.

Springback characteristics in U-channel forming of tailor rolled blank

Residual stress developed during the rolling process of tailor rolled blank （TRB） can affect the springback of finished parts considerably. Springback characteristics of unannealed and annealed TRBs were investigated by means of numerical simulation and experiments taking U-Channel as an example. TRBs were annealed by the annealing process （700 ℃, holding time 10 h）, then stamping and springback processes of unannealed and annealed TRBs were simulated, and corresponding experiments were also carried out. Effects of the transition zone length, the blank thickness, the friction coefficient and the die clearance on the springback of TRB were analyzed. The results demonstrate that the springback of TRB annealed at 700 ~C for 10 h re- duces significantly. For unannealed and annealed U-Channels, the springback of TRB U-Channel is in direct proportion to the die clearance and is in inverse proportion to the transition zone length, the blank thickness and the friction coefficient. Spring- backs of the thinner monolithic （uniform thickness） blank, the thinner side of TRB, the thicker side of TRB and the thicker monolithic blank are sorted in descending order.

Springback behavior of tailor rolled blank in U-shape forming

The springback of tailor rolled blanks with quenching and partitioning steels was investigated.In order to find out the springback behavior and related influence factors for the novel sheets,both experimental and simulation methods have been used to compare and analyze the springback characteristics of equal thickness blanks and tailor rolled blanks in U-channel forming.From the results,the overall springback angles of tailor rolled blanks at thin and thick sides are respectively 106.79° and 99.705°,which are both lower than those of the corresponding equal thickness blanks.Due to the existence of the thickness transition zone,the stress distribution in thin and thick sides of blanks is changed.The location of dangerous region in thin side of tailor rolled blanks is closer to the end of side,and the thick side moved to the middle of straight wall,which are different with the equal thickness blanks.Afterwards,the released quantitles of tangential stress and strain per unit section of blank are adopted to calculate relative springback angles and give novel evaluation criteria for qualitatively analyzing the amount of springback angles.By comparing the results,it shows that the tangential strain method is more suitable for the actual situation.

Innovative manufacturing technology enabling light weighting with steel in commercial vehicles

Improved manufacturing technology is often needed when working with high strength steel. In this re- spect manufacturing technology has to adapt to the altered （and typically reduced） formability and weldability of modern high strength steel. However, this is a rather passive approach from a manufacturing point of view. An indeed much more powerful approach is to generate synergies between innovative manufacturing technology, design and material enabling additional weight savings and efficiency gains. Laser-based material processing, in particular laser welding, offers a wide range of opportunities in this sense. Furthermore, hot stamping and roll forming open up new possibilities for advanced manufacturing of commercial vehicle components. Applications and examples of these technologies will be given in terms of producing innovative semi-products as well as final components.