A binding scheme to minimize thinning of formed tailor welded blanks / Mahmoud Samir Ahmed Elsayed Seyam ; Supervised Abdalla S. Wifi , Alaa Elmokadem , Mostafa Shazly

Thesis (M.Sc.) - Cairo University - Faculty of Engineering - Department of Mechanical Design and Production

The present work suggests a new binding scheme to reduce the thinning and weld line movement of TWBs.This scheme combines weld line constraining via counter pins while applying a lower BHF on the weaker side as compared to the stronger side via segmented binders to achieve minimum thinning in the final product. Adopting this scheme, an analytical model was developed for the plane strain 2D draw bending and the 3D box deep drawing processes to determine the required BHF and counter pin force values. Laboratory and numerical experiments were conducted to examine the developed analytical model and compare the proposed controlling scheme with other schemes.The experimental results showed that the new scheme is physically applicable and capable of providing reasonably accurate force values that sufficiently eliminate the weld line movement and enhance formability (substantial reduction in thinning).The present study showed the merits of implementing the proposed scheme in cases where large thickness and/or strength ratio of the sheets comprising the TWB exist. In such cases, conventional segmented binders along with weld line clamping technique without any variation in the applied BHF at each side cannot prevent

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