Numerical Modelling of Tailored Blank Applications for Autobody Components 1999-01-0679

Tailored Blank applications have become more and more important for the advanced light weight and cost effective steel automobile body. During the last decade, the production of Tailored Blanks with a straight weldline has been constantly increasing because their technical and economical advantages are well accepted by automobile manufacturers /1, 2, 3, 4/. But, now the body engineers prefer to have an even more flexible product with specific weldline design, according to the engineering design needs. Thyssen Krupp Stahl AG reacted quickly on this demand and now offers the new product called, Thyssen Engineered Blanks (TEB^®s), which meets almost all the needs for the design of components concerning weld-line geometry and weld-line positioning. With our new production line, both single and multiple steel sheets can now be joined together with linear weld-lines, angled weld-lines and curved laser beam weld-lines, Figure 1. To optimize the application of this new technology, the TEB^® parts development process needs to be intensively supported by numerical modeling for feasibility reasons. Given the difficulty to analyze the stamping of sheet steel with numerical methods, it is now even more challenging incorporating many different materials with different gauges, surface conditions and material properties which can be combined in one blank with unique weld-line geometry.

The paper will show how stamping simulation can support the development of components based on Thyssen Engineered Blanks technology; along with a brief focus on the important implementation of an improved material description for the numerical modeling of the stamping processes. By means of two typical applications for TEB^®s, this paper will demonstrate the significance of the stamping simulation for a shock tower and a side panel.