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Tailor welded blanks are metallic sheets made from different strengths, materials, and/or thicknesses pre-welded together before forming into the final component geometry. By combining various sheets into a welded blank, engineers are able to 'tailor' the blank so that the properties are located precisely where they are needed and cost-effective, low weight components are produced. Tailor welded blanks for advanced manufacturing examines the manufacturing of tailor welded blanks and explores their current and potential future applications.Part one investigates processing and modelling issues in tailor welded blank manufacturing. Chapters discuss weld integrity, deformation during forming and the analytical and numerical simulation modelling of tailor welded blanks for advanced manufacturing. Part two looks at the current and potential future applications of tailor welded blanks. Chapters review tailor welded blanks of lightweight metals and of advanced high-strength steel and finally discuss the uses of tailor-welded blanks in the automotive and aerospace industries.With its distinguished editors and international team of expert contributors, Tailor welded blanks for advanced manufacturing proves an invaluable resource for metal fabricators, product designers, welders, welding companies, suppliers of welding machinery and anyone working in industries that use advanced materials such as in automotive and aerospace engineering. Engineers and academics involved in manufacturing and metallurgy may also find this book a useful reference.
Examines the manufacturing of tailor welded blanks and explores their current and potential future applications
Investigates processing and quality issues in tailor welded blank manufacturing including weld integrity and deformation
Reviews both current and potential future applications of tailor welded blanks as well as specific applications in the automotive and aerospace industries
Professor Brad. L. Kinsey is Associate Professor in the Mechanical Engineering Department at the University of New Hampshire, USA. Professor Xin Wu is Associate Professor in the Department of Mechanical Engineering at Wayne State University, USA. Both editors are widely regarded for their research expertise in sheet metal and tailor welded blank forming, behaviour, processing and manufacturing.
Contributor contact detailsPrefacePart I: Processing and modelingChapter 1: Weld integrity of tailor welded blanksAbstract:1.1 Introduction1.2 Typical weld imperfections1.3 Testing methods1.4 Quality control in production1.5 ConclusionsChapter 2: Deformation of tailor welded blanks during formingAbstract:2.1 Introduction2.2 Estimation of the constitutive behavior of the weld region2.3 Methods to evaluate the weld width (or cross-sectional area) in tailor welded blanks (TWBs)2.4 Forming limits of TWBs: influence of weld orientation2.5 Weld line movement2.6 Design considerations for TWB forming2.7 Simulation of TWB forming behavior2.8 Conclusions2.9 AcknowledgmentChapter 3: Mechanics-based modeling of tailor welded blank formingAbstract:3.1 Introduction3.2 Thickness and strength ratio analysis3.3 Determination of weld line movement and forming height3.4 Determination of material draw-in ratios3.5 Determination of non-uniform binder force3.6 ConclusionsChapter 4: Numerical simulation modeling of tailor welded blank formingAbstract:4.1 Introduction4.2 Finite element method (FEM) modeling of the welded zones4.3 Material models4.4 Theoretical failure prediction of tailor welded blanks (TWBs)4.5 Some topics in design and optimization of TWBs4.6 Conclusions4.7 Future trends4.8 Sources of further information and advice4.9 AcknowledgmentsPart II: ApplicationsChapter 5: Lightweight metal alloy tailor welded blanksAbstract:5.1 Introduction5.2 Lightweight metal alloy tailor welded blanks (LWMA TWBs)5.3 LWMA TWB formability5.4 LWMA TWB benefits/recyclingChapter 6: Advanced high-strength steel tailor welded blanks (AHSS-TWBs)Abstract:6.1 Introduction to advanced high-strength steel (AHSS)6.2 Types of advanced high-strength steels and their characteristics6.3 Fabrication of advanced high-strength steels for tailor welded blanks (AHSS-TWBs)6.4 Properties and formability of AHSS-TWBs6.5 Understanding the evolution of microstructure and its impact on properties of AHSS-TWBs6.6 Other manufacturing processes related to AHSS-TWBs6.7 ConclusionsChapter 7: Tailor welded blanks for the automotive industryAbstract:7.1 Introduction7.2 Door inner example7.3 Historical perspective7.4 Advantages of tailor welded blanks (TWBs)7.5 Disadvantages of TWBs7.6 Research efforts for TWBs7.6 TWB forming methods7.8 Welding processes for TWBs7.9 Materials used to produce TWBs7.10 ConclusionsChapter 8: Tailor made blanks for the aerospace industryAbstract:8.1 Introduction8.2 The tailor made blank (TMB) concept and the aircraft industry8.3 Future trends8.4 Conclusions8.5 AcknowledgementsIndex