Skip to main content
SpringerLink
Log in

Effect of Circular Hole Discontinuities on Crushing Characteristics of Combined Geometry Shells of Tailor Welded Blanks

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

In this research work, two-stage drawing was employed to fabricate combined geometry shells with hemispherical and cylindrical segments using two types of laser welded blanks, namely similar thickness (LWBs) and dissimilar thickness (LWTBs) of extra deep drawing steels. Four diametrically opposing circular holes of 4 mm and 8 mm were drilled in the cylindrical portion. These shells were quasi-statically crushed between two flat platens to investigate the effect of the presence of hole on crush characteristics such as collapse modes and load–displacement response. The collapse of LWTB shells started with an inward dimple in the hemispherical section and followed by uneven and partial folding of the cylindrical section due to the non-uniform thickness variation across the weld zone. However, it was identified that the presence of 8 mm holes promoted progressive folding with a uniform load–displacement response, while uneven and partial folding was observed in shells with 4 mm holes. The use of Stoughton non-associated flow rule (S-NAFR) in finite element modeling predicted the non-uniform thickness variation and earring profile of the LWTB shells better than Hill48 model. Also, the load–displacement response and modes of collapse during the crushing of all the shells were predicted well using the S-NAFR model. Based on the above findings, it was perceived that the circular holes could be inserted as discontinuities in LWTB shells to suppress the effect of non-uniform thickness distribution on the crushing characteristics.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. X. Song, G. Sun, and Q. Li, Sensitivity Analysis and Reliability Based Design Optimization for High-Strength Steel Tailor Welded Thin-Walled Structures under Crashworthiness, Thin-Walled Struct., 2016, 109, p 132–142. https://doi.org/10.1016/j.tws.2016.09.003

    Article  Google Scholar 

  2. M. Merklein, M. Johannes, M. Lechner, and A. Kuppert, A Review on Tailored Blanks—Production, Applications and Evaluation, J. Mater. Process. Technol., 2014, 214(2), p 151–164. https://doi.org/10.1016/j.jmatprotec.2013.08.015

    Article  Google Scholar 

  3. P. Kaczyński, Z. Gronostajski, and S. Polak, Progressive Crushing as a New Mechanism of Energy Absorption. The Crushing Study of Magnesium Alloy Crash-Boxes, Int. J. Impact Eng., 2019, 124(February 2018), p 1–8.

    Article  Google Scholar 

  4. K. Bandyopadhyay, S.K. Panda, and P. Saha, Investigations into the Influence of Weld Zone on Formability of Fiber Laser-Welded Advanced High Strength Steel, J. Mater. Eng. Perform., 2014, 23(4), p 1465–1479.

    Article  CAS  Google Scholar 

  5. B.S. Katiyar, S.K. Panda, and P. Saha, Quasi-Static Crushing Behavior of Stretch Formed Domes of Laser Welded Tailored Blanks, Thin-Walled Struct., 2021, 159(November 2020), p 107288.

    Article  Google Scholar 

  6. M.A. Ahmetoglu, D. Brouwers, L. Shulkin, L. Taupin, G.L. Kinzel, and T. Altan, Deep Drawing of Round Cups from Tailor-Welded Blanks, J. Mater. Process. Tech., 1995, 53(3–4), p 684–694.

    Article  Google Scholar 

  7. S. Chatterjee, R. Saha, M. Shome, and R.K. Ray, Evaluation of Formability and Mechanical Behavior of Laser-Welded Tailored Blanks Made of Interstitial-Free and Dual-Phase Steels, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., 2009, 40(5), p 1142–1152.

    Article  Google Scholar 

  8. U. Reisgen, M. Schleser, O. Mokrov, and E. Ahmed, Optimization of Laser Welding of DP/TRIP Steel Sheets Using Statistical Approach, Opt. Laser Technol., 2012, 44(1), p 255–262. https://doi.org/10.1016/j.optlastec.2011.06.028

    Article  CAS  Google Scholar 

  9. A.A. Zadpoor, J. Sinke, and R. Benedictus, Mechanics of Tailor Welded Blanks: An Overview, Key Eng. Mater., 2007, 344, p 373–382. https://doi.org/10.4028/www.scientific.net/KEM.344.373

    Article  Google Scholar 

  10. M. Abbasi, S.R. Hamzeloo, M. Ketabchi, M.A. Shafaat, and B. Bagheri, Analytical Method for Prediction of Weld Line Movement During Stretch Forming of Tailor-Welded Blanks, Int. J. Adv. Manuf. Technol., 2014, 73(5–8), p 999–1009.

    Article  Google Scholar 

  11. Y.M. Heo, S.H. Wang, H.Y. Kim, and D.G. Seo, The Effect of the Drawbead Dimensions on the Weld-Line Movements in the Deep Drawing of Tailor-Welded Blanks, J. Mater. Process. Technol., 2001, 113(1–3), p 686–691.

    Article  Google Scholar 

  12. C.H. Cheng, L.C. Chan, and C.L. Chow, Weldment Properties Evaluation and Formability Study of Tailor-Welded Blanks of Different Thickness Combinations and Welding Orientations, J. Mater. Sci., 2007, 42(15), p 5982–5990.

    Article  CAS  Google Scholar 

  13. H. Moayedi, R. Darabi, A. Ghabussi, M. Habibi, and L.K. Foong, Weld Orientation Effects on the Formability of Tailor Welded Thin Steel Sheets, Thin-Walled Struct., 2020, 149(January), p 106. https://doi.org/10.1016/j.tws.2020.106669

    Article  Google Scholar 

  14. K. Bandyopadhyay, S.K. Panda, P. Saha, and G. Padmanabham, Limiting Drawing Ratio and Deep Drawing Behavior of Dual Phase Steel Tailor Welded Blanks: FE Simulation and Experimental Validation, J. Mater. Process. Technol., 2015, 217, p 48–64. https://doi.org/10.1016/j.jmatprotec.2014.10.022

    Article  CAS  Google Scholar 

  15. F. Xu, G. Sun, G. Li, and Q. Li, Experimental Study on Crashworthiness of Tailor-Welded Blank (TWB) Thin-Walled High-Strength Steel (HSS) Tubular Structures, Thin-Walled Struct., 2014, 74, p 12–27.

    Article  Google Scholar 

  16. A.G. Mamalis, D.E. Manolakos, K.N. Spentzas, M.B. Ioannidis, S. Koutroubakis, and P.K. Kostazos, The Effect of the Implementation of Circular Holes as Crush Initiators to the Crushing Characteristics of Mild Steel Square Tubes: Experimental and Numerical Simulation, Int. J. Crashworthiness, 2009, 14(5), p 489–501.

    Article  Google Scholar 

  17. B. Arnold and W. Altenhof, Experimental Observations on the Crush Characteristics of AA6061 T4 and T6 Structural Square Tubes with and without Circular Discontinuities, Int. J. Crashworthiness, 2004, 9(1), p 73–87.

    Article  Google Scholar 

  18. H. Taghipoor, A. Ghiaskar, and A. Shavalipour, Crashworthiness Performance of Thin-Walled, Square Tubes with Circular Hole Discontinuities under High-Speed Impact Loading, Int. J. Crashworthiness, 2021 https://doi.org/10.1080/13588265.2021.1981125

    Article  Google Scholar 

  19. H. Nikkhah, A. Baroutaji, and A.G. Olabi, Crashworthiness Design and Optimisation of Windowed Tubes under Axial Impact Loading, Thin-Walled Struct., 2019, 142(April), p 132–148. https://doi.org/10.1016/j.tws.2019.04.052

    Article  Google Scholar 

  20. A.A. Zadpoor, J. Sinke, and R. Benedictus, Finite Element Modeling and Failure Prediction of Friction Stir Welded Blanks, Mater. Des., 2009, 30(5), p 1423–1434. https://doi.org/10.1016/j.matdes.2008.08.018

    Article  CAS  Google Scholar 

  21. F. Barlat, J.C. Brem, J.W. Yoon, K. Chung, R.E. Dick, D.J. Lege, F. Pourboghrat, S.H. Choi, and E. Chu, Plane Stress Yield Function for Aluminum Alloy Sheets—Part 1: Theory, Int. J. Plast., 2003, 19(9), p 1297–1319.

    Article  CAS  Google Scholar 

  22. F. Barlat, H. Aretz, J.W. Yoon, M.E. Karabin, J.C. Brem, and R.E. Dick, Linear Transfomation-Based Anisotropic Yield Functions, Int. J. Plast., 2005, 21(5), p 1009–1039.

    Article  CAS  Google Scholar 

  23. K. Hariharan, N.T. Nguyen, N. Chakraborti, M.G. Lee, and F. Barlat, Multi-Objective Genetic Algorithm to Optimize Variable Drawbead Geometry for Tailor Welded Blanks Made of Dissimilar Steels, Steel Res. Int., 2014, 85(12), p 1597–1607.

    Article  CAS  Google Scholar 

  24. D. Kim, W. Lee, J. Kim, C. Kim, and K. Chung, Formability Evaluation of Friction Stir Welded 6111–T4 Sheet with Respect to Joining Material Direction, Int. J. Mech. Sci., 2010, 52(4), p 612–625. https://doi.org/10.1016/j.ijmecsci.2010.01.001

    Article  Google Scholar 

  25. W.A. Spitzig, Effect of Hydrostatic Pressure on Plastic-Flow Properties of Iron Single Crystals, Acta Metall., 1979, 27(4), p 523–534.

    Article  CAS  Google Scholar 

  26. W.A. Spitzig, R.J. Sober, and O. Richmond, The Effect of Hydrostatic Pressure on the Deformation Behavior of Maraging and HY-80 Steels and Its Implications for Plasticity Theory, Metall. Trans. A, 1976, 7(10), p 1703–1710.

    Article  Google Scholar 

  27. W.A. Spitzig and O. Richmond, The Effect of Pressure on the Flow Stress of Metals, Acta Metall., 1984, 32(3), p 457–463.

    Article  CAS  Google Scholar 

  28. T.B. Stoughton and J.W. Yoon, A Pressure-Sensitive Yield Criterion under a Non-Associated Flow Rule for Sheet Metal Forming, Int. J. Plast., 2004, 20(4–5), p 705–731.

    Article  CAS  Google Scholar 

  29. J. Min, J.E. Carsley, J. Lin, Y. Wen, and B. Kuhlenkötter, A Non-Quadratic Constitutive Model under Non-Associated Flow Rule of Sheet Metals with Anisotropic Hardening: Modeling and Experimental Validation, Int. J. Mech. Sci., 2016, 119, p 343–359.

    Article  Google Scholar 

  30. M. Safaei, J.W. Yoon, and W. De Waele, Study on the Definition of Equivalent Plastic Strain under Non-Associated Flow Rule for Finite Element Formulation, Int. J. Plast., 2014, 58, p 219–238. https://doi.org/10.1016/j.ijplas.2013.09.010

    Article  CAS  Google Scholar 

  31. A. Bouhamed, H. Jrad, L. Ben Said, M. Wali, and F. Dammak, A Non-Associated Anisotropic Plasticity Model with Mixed Isotropic-Kinematic Hardening for Finite Element Simulation of Incremental Sheet Metal Forming Process, Int. J. Adv. Manuf. Technol., 2019, 100(1–4), p 929–940.

    Article  Google Scholar 

  32. T.B. Stoughton, A Non-Associated Flow Rule for Sheet Metal Forming, Int. J. Plast., 2002, 18(5–6), p 687–714.

    Article  Google Scholar 

  33. K. Hariharan, N.T. Nguyen, N. Chakraborti, F. Barlat, and M.G. Lee, Determination of Anisotropic Yield Coefficients by a Data-Driven Multiobjective Evolutionary and Genetic Algorithm, Mater. Manuf. Process., 2015, 30(4), p 403–413.

    Article  CAS  Google Scholar 

  34. D. Anand, D.L. Chen, S.D. Bhole, P. Andreychuk, and G. Boudreau, Fatigue Behavior of Tailor (Laser)-Welded Blanks for Automotive Applications, Mater. Sci. Eng. A, 2006, 420(1–2), p 199–207.

    Article  Google Scholar 

  35. J. Rojek, M. Hyrcza-Michalska, A. Bokota, and W. Piekarska, Determination of Mechanical Properties of the Weld Zone in Tailor-Welded Blanks, Arch. Civ. Mech. Eng., 2012, 12(2), p 156–162. https://doi.org/10.1016/j.acme.2012.04.004

    Article  Google Scholar 

  36. L.C. Chan, S.M. Chan, C.H. Cheng, and T.C. Lee, Formability and Weld Zone Analysis of Tailor-Welded Blanks for Various Thickness Ratios, J. Eng. Mater. Technol., 2005, 127(2), p 179. https://doi.org/10.1115/1.1857936

    Article  CAS  Google Scholar 

  37. S. Basak and S.K. Panda, Implementation of Yld96 Anisotropy Plasticity Theory for Estimation of Polar Effective Plastic Strain Based Failure Limit of Pre-Strained Thin Steels, Thin-Walled Struct., 2018, 126(April 2017), p 26–37.

    Article  Google Scholar 

  38. ASTM E-517, Standard Test Method for Plastic Strain Ratio r for Sheet Metal, ASTM international, 2010, p 1–8.

  39. J. Kim, Q.T. Pham, J. Ha, and Y.S. Kim, Constitutive Modeling of Commercial Pure Titanium Sheet Based on Non-Associated Flow Rule and Differential Hardening, Int. J. Mech. Sci., 2022, 230(June), p 107549. https://doi.org/10.1016/j.ijmecsci.2022.107549

    Article  Google Scholar 

  40. A. Tasdemirci, S. Sahin, A. Kara, and K. Turan, Crushing and Energy Absorption Characteristics of Combined Geometry Shells at Quasi-Static and Dynamic Strain Rates: Experimental and Numerical Study, Thin-Walled Struct., 2015, 86, p 83–93. https://doi.org/10.1016/j.tws.2014.09.020

    Article  Google Scholar 

  41. D.M. Neto, M.C. Oliveira, J.L. Alves, and L.F. Menezes, Influence of the Plastic Anisotropy Modelling in the Reverse Deep Drawing Process Simulation, Mater. Des., 2014, 60, p 368–379. https://doi.org/10.1016/j.matdes.2014.04.008

    Article  Google Scholar 

  42. J. Zhu, Y. Xia, H. Luo, G. Gu, and Q. Zhou, Influence of Flow Rule and Calibration Approach on Plasticity Characterization of DP780 Steel Sheets Using Hill48 Model, Int. J. Mech. Sci., 2014, 89, p 148–157.

    Article  Google Scholar 

Download references

Acknowledgments

The authors are grateful for the support provided by Prof. Shamik Basak of Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, India, during the FE simulations of this study.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, 721302, India

    Bhupesh Singh Katiyar, Sushanta Kumar Panda & Partha Saha

Authors
  1. Bhupesh Singh Katiyar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sushanta Kumar Panda
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Partha Saha
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Sushanta Kumar Panda.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Katiyar, B.S., Panda, S.K. & Saha, P. Effect of Circular Hole Discontinuities on Crushing Characteristics of Combined Geometry Shells of Tailor Welded Blanks. J. of Materi Eng and Perform 33, 3034–3049 (2024). https://doi.org/10.1007/s11665-023-08157-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-023-08157-0

Keywords

Search

Navigation