Study On The Optimization Of Stamping Formability Process Parameters Of The Inside Door Panels Made Of Tailor-welded Blanks

In recent years, with the world increasingly emphasizing on the environmental protection, energy and security, the three main objectives of automobile industry development are as follows: reducing vehicle weight, saving energy, lowering energy consumption and reducing pollutants discharge, and improving vehicle safety performance. In the low-carbon economic development trend, the tailor welded blanks stamping technology wichi is combined with traditional materials and manufacturing processes is widely used. While, tailor welded blank technology of metal forming gradually unfolded.This paper elaborates the applications of the tailor welded blanks in the auto body designs and manufacturings,and then anylysis the affections of the different sheet thickness ratio, different sheet strength ratio, different weld-line locations, different blank holder force, different drawbead and other inherent parameters or tailor welded blanks forming process parameters on the TWB forming progress. As the inside door part ,which is made by TWB,has some complex shaped holes,it is difficult to assess the performance of TWB forming.We can predict the performance ot the insede door by the proposed use of advanced numerical simulation finite element analysis software eta / Dynaform.Firstly, takes the application of TWBs in the auto body design and manufacture as an example, and anylasis the forming limit and the amount of weld-line movement rules by various factors of the tailor-welded box-shaped parts forming progress.The author studys on the forming limit and the amount of weld-line movement of the tailor-welded box-shaped parts with different thickness, different different strength ,different weld-line location, different BHF, different drawbead resistance, different friction by the DOE and eta/Dynaform software.By Using the variance analysis ,it can conlude the forming limit and the amount of weld-line movement rules .And we know that, in order to ensure the tailor-welded blank auto body parts forming quality, sheet metal thickness ratio should not be too small, usually not less than 0.5, sheet strength should be between 0.8 and 1.3, and the location of weld lines could be in the thick blank side.At last, the instruction of method and theory for the TWB Part's design and production in reality is provided by the conclusion which is got by the square box part.Through numerical simulation analysis on the inside door made by the TWB,we can conclude that the rational design of deep drawing bead and the stiffener, a reasonable blank holder force, combined with using second drawing process,we can improve the forming quality reduce the weld-line movement.