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Accurate Simulation of Tailor-Welded-Blanks to Reduce Process Design Time for the Sheet Pressing Industry
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The main objective of the SIM-TWB project was to improve the design and manufacture of tailor-welded blank (TWB) components by using accurate numerical simulation and concurrent engineering methodologies.
The sheet pressing operations of tailor-welded blanks were predicted and optimised via simulation in order to obtain a viable product and process design prior to the construction of costly physical prototypes.
However, in order to successfully use these methodologies it was crucial to carry out accurate modelling of the weld seam including the effects of different sheet alignment, type of welding, heat affected zone and the sheet materials.
Strategic Objectives:
  Improving concurrent engineering practices within the tailor-welded-blank (TWB) manufacturing sector →reduction of costs, quality improvement and reduction of time to-market;
“right-first-time” design, providing accurate simulation for the prediction of tailor-blank manufacture → problems are solved prior to the first prototype and
should enable physical die trialing to be reduced to a maximum of 2 trials;
Improving welding technology (speed, methods and curved weld-seams) to enable the freedom of choice in the use of high-performance steels and
aluminium for tailor-blanks
Reduction of vehicle weight while increasing safety and reducing fuel consumption;
Direct benefits to the SMEs:
Effective design, development and implementation of new manufacturing techniques for TWBs;
Improved understanding and characterisation of laser and friction stir welding techniques;
Improved die design to control twisting and movement of weld seam;
Reduced trial-and-error and manufactured prototypes implying reduced time-to-market;
Confident use of high-performance steels and aluminium in tailor-blanks;
Improved and knowledge-based product/process design methodology from TWB using CAD-CAE;
Overall reduction of manufacturing costs.
The SIM-TWB project lasted for 24 months – from 01 September 2006 to 31 August 2008.
 Project Info |
