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Experimental and numerical investigation of forming defects and stress analysis in laser-welded blanks during deep drawing process

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Abstract

In this study, welding and forming defects in a deep drawing process of laser-welded blanks (LWBs) are investigated both experimentally and numerically. LWB is used to achieve minimum distortion and desirable weld quality. However, some unfavorable residual stresses are added throughout the forming operations, which decrease the lifetime of LWBs. The objective of this study is to estimate the effect of five significant process parameters on forming defects during the welding and forming of LWBs. To this end, the hole-drilling method is utilized to determine experimentally the residual stresses in diverse zones of LWBs. Besides, the laser beam welding and forming processes are simulated by SIMUFACTTM package and ABAQUSTM software, respectively. The validation results show that the proposed model is very promising to estimate residual stresses for LWBs in industrial parts, especially in automobile industries. Studying the effect of varying process factors, it is noticed that the joining quality of the weld region is enhanced by applying the high-level spot size which has an optimum range to prevent the probability of brittle crack.

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All data, material, and codes used in this paper are available.

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Authors and Affiliations

  1. Department of Mathematics, Computer Science and Engineering, Université du Québec à Rimouski, Rimouski, Québec, Canada

    Ahmad Aminzadeh, Sasan Sattarpanah Karganroudi & Noureddine Barka

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  1. Ahmad Aminzadeh
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  2. Sasan Sattarpanah Karganroudi
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  3. Noureddine Barka
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Contributions

The authors’ contributions are as following: AA conceived, planned, and carried out data curation, methodology, software, formal analysis, and writing the original manuscript; SSK contributed actively in data curation, developing methodology, experimental and numeric analyses, and writing the manuscript; NB contributed in supervision, writing, review, and editing the manuscript; all authors provided critical feedback and helped shape the research, analysis, and manuscript.

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Correspondence to Sasan Sattarpanah Karganroudi.

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Aminzadeh, A., Sattarpanah Karganroudi, S. & Barka, N. Experimental and numerical investigation of forming defects and stress analysis in laser-welded blanks during deep drawing process. Int J Adv Manuf Technol 117, 1193–1207 (2021). https://doi.org/10.1007/s00170-021-07767-z

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