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Experimental and numerical analyses on crushing behaviour of drawn cups of laser welded tailored blanks under axial loading

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Abstract

It is imperative to characterize the crushing behaviour of deep drawn components of tailor welded blanks for their wide applications in different autobody structures. In the present work, extra deep drawing steel sheets were laser welded to produce welded blanks of similar thickness and dissimilar thickness (LWTBs), and these were deformed using a two stage deep drawing setup to fabricate geometrically similar drawn cups consisting of both hemispherical and cylindrical segments. Subsequently, these drawn cups were axially crushed between two flat platens to study collapse modes, load–displacement responses and energy absorption capabilities. The collapse of the drawn cups was found to onset with an inward dimpling of the hemispherical segment. As deformation progressed, the folding of cylindrical section occurred either axisymmetrically or unevenly based on the extent of non-uniform thickness variations across the weld zone (WZ). It was also found that the load–displacement response and energy absorption of the cups were enhanced because of the presence of WZ and thickness difference in LWTBs. Also, finite element-based numerical models were developed to collate the prediction capabilities of three different anisotropic material models viz. Hill48, YLD89, and Stoughton non-associated flow rule (S-NAFR)-based model. All these material models were successfully calibrated to predict the collapse modes, but the S-NAFR model was found to closely predict the load–displacement curves and energy absorption. Furthermore, the assessment of specific energy absorption and crushing force efficiency suggested that lightweight LWTB components can be fabricated with improved crashworthiness performance using sheet materials of different thickness.

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Acknowledgements

The authors are greatly thankful to Prof. Shamik Basak of Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, India for his help in FE simulations of this study.

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No funding was received for conducting this study.

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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

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  1. Bhupesh Singh Katiyar
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Contributions

Conceptualization: Bhupesh Singh Katiyar, Sushanta Kumar Panda, Partha Saha; methodology: Bhupesh Singh Katiyar, Sushanta Kumar Panda, Partha Saha; formal analysis and investigation: Bhupesh Singh Katiyar, Sushanta Kumar Panda; writing—original draft preparation: Bhupesh Singh Katiyar; writing—review and editing: Bhupesh Singh Katiyar, Sushanta Kumar Panda, Partha Saha; Resources: Sushanta Kumar Panda, Partha Saha; supervision: Sushanta Kumar Panda, Partha Saha.

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Correspondence to Sushanta Kumar Panda.

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Katiyar, B.S., Panda, S.K. & Saha, P. Experimental and numerical analyses on crushing behaviour of drawn cups of laser welded tailored blanks under axial loading. Archiv.Civ.Mech.Eng 22, 211 (2022). https://doi.org/10.1007/s43452-022-00537-y

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