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Co-operative Research Project

ACCURATE SIMULATION OFTAILOR-WELDED-BLANKS

TO REDUCE PROCESS DESIGN TIMEFOR THE SHEET PRESSING INDUSTRY

SIM-TWB no: 032657

Deliverable D19:Final Publishable Project Report

Partner: P01: QuantechMain author: Laurentiu NeamtuE-mail: [email protected] authors: Gino Duffett

[email protected] number: TEC-7-01 Review: 01Date: September 2008

mailto:[email protected]

mailto:[email protected]

SIM-TWB no. 032657 Report number: TEC-7-01

Table of Contents1. Project Summary_____________________________________________________________3

1.1 Project objectives_________________________________________________________3

1.2 Contractors involved______________________________________________________4

1.3 Work performed and results achieved_______________________________________5

1.4 Anticipated usage of the main exploitable result_______________________________5

2. Project work completed________________________________________________________6

2.1 Quantech ATZ___________________________________________________________6

2.2 ComStamp_____________________________________________________________10

2.3 Prosit__________________________________________________________________12

2.4 Formpol-VAB__________________________________________________________13

2.5 Lasindustria____________________________________________________________14

2.6 EWF__________________________________________________________________15

2.7 CIMNE________________________________________________________________19

2.8 IPPT-PAN_____________________________________________________________22

2.9 PS____________________________________________________________________24

2.10 IST____________________________________________________________________27

3. Final project outcome and Conclusions__________________________________________30

4. Future_____________________________________________________________________33

5. References_________________________________________________________________35

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1. Project SummaryThe SIM-TWB project was a 2 year project that finished end of August 2008. The project was financed by the EC as a Cooperative Research Project within the Sixth Framework Programme Horizontal Research Activities Involving SMEs. The project had a total of 10 partners including 5 industrial SME partners and 1 industrial federation.

1.1 Project objectivesThe full exploitation of the advantages offered by tailor-blanks is presently limited due to the design and production complications that currently exist. Without adequate simulation to reduce the project time, costly trial-and-error methods are required to enhance the process and make the changes necessary. The need for the SIM-TWB project is therefore clear: advances in simulation technology must be made soon in order to take full advantage of concurrent engineering approaches to reduce time and cost, improve quality and safety and enable advances in tailor-welded-blank technology and usage.The strategic objectives of the SIM-TWB project are (in order of importance): improving concurrent engineering practises within the tailor-welded-blank (TWB)

manufacturing sector in order to reduce costs, improve quality and reduce time-to-market. The aim by the end of the project is to reduce the current average time to produce a working die by at least 30-40%.

providing accurate simulation for the prediction of tailor-blank manufacture therefore achieving a nearly “right-first-time” design. This will be possible by the end of the project so that more than 80% of problems are solved prior to the first prototype and should enable physical die trialling to be reduced to a maximum of 2 trials.

improving welding technology (speed, methods and curved weld-seams) to enable the freedom of choice in the use of high-performance steels and aluminium for tailor-blanks within industrial production lines, without any reduction in production speed.

reduction of vehicle weight while increasing safety and reducing fuel consumption. It is difficult to quantify the amount of vehicle weight that can saved but it is estimated that a further 10%-20% weight reduction may be achieved by using high-performance materials – this should be achievable without increasing the overall material cost that is currently about €1250 of sheet steel per passenger vehicle. Fuel usage and emission will be reduced in the same proportion.

Achieving the first three objectives will create a saving of €120.000 for each die manufactured if only 2 trails are required (currently there are about 4 trails) or a saving of €170.000 if the process is really “right-first-time”. A typical SME die manufacturer or designer such as those in this project usually deal with about 15 to 20 parts (at least) per year of which 2 to 4 could be tailor blanks (depending on their size and expertise). This could imply a saving of at least €290.000 annually and possibly €1.000.000 for 1 company if they made the same savings on about half of their total production. A simple calculation shows that the cost of the SIM-TWB project will be rapidly recovered in this way.The strategic innovative step lies in developing a simulation software to accurately model the tailor-blank stamping process so that aspects such as curved weld seams and the use of high-performance (high carbon) steels and aluminium can be applied in future production. Based on current simulation practises, it is estimated that these advances in the modelling of tailor blanks due to the advances in the SIM-TWB project will: provide at the very least the same accuracy compared to current complex models requiring

transition zones, changes in material characteristics, long CPU times, etc.

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remove the need of modelling the weld seam as a transition zone with its material constitutive model or models and the inclusion of additional stiffener elements to model the bending and torsion stiffness along the weld. The number of parameters may be reduced by as much as 90%.

reduce engineer time in preparing the initial model by at least 70%, reduce the CPU time required for a single simulation run by approximately 20% reducing the

calculation time for the weld seam, reduce the time required in obtaining the final solution by at least 60%, in this manner an engineer can at least double the number “what-if” simulations carried out and

therefore has more possibilities of optimising the product and process (real example: the weight of a door panel was reduced by 34% instead of 25% when the number of trial designs was doubled).

Improved industrial practises will result from the project relating to optimum tool design and the use of simulation for the utilization of tailor-blanks. Achieving a nearly “right-first-time” design, or more than 80% of problems solved prior to the first prototype, will produce huge economic savings for the companies involved and will have a positive psychological effect on the workforce due to the fact that they will be producing dies that work rather than becoming frustrated with ones that are difficult to set up correctly (this can be evaluated by interviews with personnel). The trend towards more knowledge-based and technology-based engineering companies is clear and this will enable the technology to be fully exploited and advanced by extending its use to other areas such as the use of aluminium. The SIM-TWB project objective combines new industrial design tools and simulation development to provide the following direct benefits to the SMEs: effective design, development and implementation of new manufacturing techniques for TWBs:

curved weld seams, FSW welding, stamping of aluminium tailor-blanks, improved understanding and characterisation of laser and friction stir welding techniques, improved die design to control twisting and movement of weld seam, reduced trial-and-error and manufactured prototypes implying reduced time-to-market, confident use of high-performance steels and aluminium in tailor-blanks, improved and knowledge-based product/process design methodology from TWB using CAD-

CAE and a closer working relationship between clients and providers, reduced cost of overall cost of manufacture.

1.2 Contractors involvedThe project had a total of 10 contractors: 5 SMEP contractors, 1 Other contractor (a Federation) and 4 Research Contractors. Quantech ATZ was the project coordinator and the contractors were: Role Type No. Name Short name CountryCO SMEP 1 Quantech ATZ Quantech ESCR SMEP 2 ComStamp ComStamp ITCR SMEP 3 Progettazione Stampi Ingegnerizzazioni

Traferimento TechnologieProsit IT

CR OTH 4 Magna Cosma International, Formpol Formpol-VAB PLCR SMEP 5 Lasindustria Lasindustria PTCR OTH 6 European Federation for Welding, Joining and

CuttingEWF PT

CR RTD 7 Centro Internacional de Métodos Numéricos en Ingeniería

CIMNE ES

CR RTD 8 Instytut Podstawowych Problemów Techniki Polska Akademia Nauk

IPPT-PAN PL

CR RTD 9 Politechnika Slaska PS PLCR RTD 10 Instituto Superior Técnico IST PT

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1.3 Work performed and results achievedThe project work done over the period was divided into the following work-package tasks:

WP1. SOFTWARE & EXPERIMENTAL SPECIFICATIONSA complete specification for weld modelling including the mathematical/program specification of weld modelling and the experimental/simulation plan for weld seam characterisation. A compilation of the SME technical requirements in order to cover most of the needs related to the numerical simulation of the tailor-welded blanks usage in industry.

WP2. EXPERIMENTAL & NUMERICAL CHARACTERISATIONThe characterisation of welding processes and materials via experimentation, including characterisation of laser and diode laser welding processes for steels and FSW welding processes for high-performance materials.

WP3. NUMERICAL DEVELOPMENT OF MODELSThe weld seam numerical behaviour model and the weld macroscopic constitutive model with initial verification were created and the initial software version for tailor-blank modelling was released, including training documentation on tailor-blank modelling.

WP4. INDUSTRIAL TECHNOLOGICAL ENHANCEMENTSOn the practical side the SME partners completed many studies looking at enhancements for the press tooling for tailor-blanks utilizing steels and the applicability of high-performance materials for tailor-blanks.

WP5. INDUSTRIAL IMPLEMENTATIONTraining was carried out so that the SMEs and RTDs learnt how to use the software that was created. The software was used for carrying out pilot studies of tailor-blank modelling.

WP6. DISSEMINATION AND EXPLOITATIONGeneral dissemination and exploitation actions.

WP7. PROJECT MANAGEMENTProject management and organization of meetings.

1.4 Anticipated usage of the main exploitable resultThe main project result was the useable software modules which all the SMEs will exploit directly by installing and utilising in-house. However, they do not wish to involve themselves in any proprietary issues since software requires maintenance, continual development and support for which they do not have the required structures or personnel. It has therefore been agreed that Quantech assume ownership of the tailor-blank software modules, integrate them within Stampack, and protect them as necessary. Quantech will, on the other hand, provide special terms and usage conditions for the SMEs without whom these modules could not be developed, but who acknowledge the fact that the SME rights lie with the direct results of the SIM-TWB project. The consortium also agrees that the RTD Performers have special terms for the usage of the software modules and the Stampack software for academic and R&D purposes since it is natural that future collaborations will benefit all parties.

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2. Project work completedThis chapter details the project objectives and work completed by each Partner, showing their main emphasis and the links/collaboration between the work and partners.

2.1 Quantech ATZThis section overviews the project work carried out by Partner P01: Quantech ATZ (Spain), an SME partner and the coordinator of the project.

2.1.1 Quantech ATZ work objectivesAs a technology transfer and software development company, the main objective related to the work in the project is to offer an updated product for the market in order to gain reputation and increase sales in the 12 months period after the end of the project by 10-15%. This should be accomplished with a product that may:- improve concurrent engineering practises within the tailor-welded-blank (TWB) manufacturing sector in order to reduce costs, improve quality and reduce time-to-market. The aim by the end of the project is to reduce the current average time to produce a working die by at least 30-40%;- provide an improved simulation tool environment for the accurate simulation for the prediction of tailor-blank manufacture therefore achieving a nearly “right-first-time” design. This should allow that more than 80% of problems are solved prior to the first prototype and should enable physical die trialling to be reduced to a maximum of 2 trials.Based on the advances in the project, the simulation tool will:- provide at the very least the same accuracy compared to current complex models requiring transition zones, changes in material characteristics, long CPU times, etc;- remove the need of modelling the weld seam as a transition zone with its material constitutive model or models and the inclusion of additional stiffener elements to model the bending and torsion stiffness along the weld;- reduce engineer time in preparing the initial model;- reduce the CPU time required for a single simulation run;- reduce the time required in obtaining the final solution to allow an engineer that at least can double the number of “what-if” simulations carried out and therefore to have more possibilities of optimising the product and process.

2.1.2 Quantech ATZ work done and results contributedQuantech has been responsible for the management of the SIM-TWB project and acted in the name of the Consortium for the daily reporting to the Commission as well as for any external relationship. Project management work included the setting up of a management structure, the overall co-ordination of the technical work of the different work packages, the organisation of project meetings, the preparation of technical and management project reports and the administration of project finances. As PM, Quantech has been responsible for defining the QA procedures and guidelines for the performance of the project tasks, the preparation and delivery of the technical and financial reports and for defining internal validation check procedures for assessment of the development of the different RTD and administrative activities in the project.With respect to the technical work and results contributed, Quantech has been involved in:

WORKPACKAGE 1 (WP1) – SOFTWARE & EXPERIMENTAL SPECIFICATIONSWP1-1 Specification for tailor-blank modelling (TL) : the mathematical definition of the model to be used for the weld seam. This included the sheet alignment, welding process and the heat affected zone aspects. The definition of the program structure, input parameters, user interface,

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weld seam database requirements and user definition of the tailor-blanks has been performed. This specification assisted the definition of the experimental work required in order to characterise these models properly;WP1-3 SME requirements (TL): the definition of requirements for the SIM-TWB software algorithms/usage from the point of view of all the SMEs participating in the project. This included the definition of specific features from the operability and points of view which favour the dissemination and internal/external exploitation of the software by the participating SMEs;WP1-4 Assessment and evaluation (TL): the current commercial version of the software has been installed at the SMEs and training courses have been held to start using the simulation software. Work in this task included the definition of rules for quality assurance (QA) and internal assessment of the development of the project tasks. Quantech has been responsible for defining the QA procedures and guidelines for the performance of the project tasks, the preparation and delivery of the technical and financial reports and the organization and performance of the dissemination and exploitation activities;The main results of the work performed during WP1 have been synthetically presented in deliverables TEC-1-02 (D01) and TEC-1-03 (D02) with Quantech as main author.

Finite element models

WORKPACKAGE 2 (WP2): EXPERIMENTAL & NUMERICAL CHARACTERISATION WP2-1 Experimental work on tailor-blank welds: the characterisation of the weld seam model in terms of sheet alignment and bending effects. Quantech assisted CIMNE for the material testing possibilities in order to insure for a backup testing capacities on laboratory tailor-blanks in order to determine their characteristics;WP2-4 FEM studies to characterise welding: finite element method (FEM) based numerical simulations have been used as an additional aid to study the complex thermal-mechanical-metallurgical interaction during welding. These studies made possible to carry out parameter studies more cheaply than by doing so experimentally. These studies have been done working closely with IPPT-PAN. Temperature distribution and evolution has been analysed. Residual stresses have been obtained in the weld zone.The main results of the work performed during WP2 have been synthetically presented in deliverables TEC-2-04 (D03) and TEC-2-05 (D04) with Quantech as contributor.

WORKPACKAGE 3 (WP3): NUMERICAL DEVELOPMENT OF MODELSWP3-1 Development of weld macroscopic constitutive model: the improvement of the model formulated together with CIMNE, IPPT and IST to the mathematical formulation of the macroscopic material behaviour of the weld heat affected zone (HAZ). It is a simple model, with few input parameters, relatively accurate but simple for non weld-expert users;WP3-2 Development of complete weld seam behaviour model: the inclusion of the combined geometrical effects such as sheet alignments (different sheet thicknesses welding top-top, bottom-bottom, centre-centre, etc.) that produce bending and torsion forces along the weld with the weld material constitutive effects (virgin material, HAZ, transition zone, etc.) which are being developed in WP3-1. A series of preliminary tests have been carried out and simulations of the experimental work on the blanks will provide initial verification that the models work correctly. The numerical

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model was completed in the finite element code Stampack. Verification tests have been completed to show that the numerical model correctly represents complex deformation of TWBs;WP3-3 Adaptation of user-interface for tailor-blank modelling (TL): the adaptation of the already existing Stampack user interface to enable the user to easily define tailorblanks and the characteristics of the weld-line. The basic idea is that the user define the different blank zones as well as the weld-seam – this will obviously be more complicated that the current method of just defining the blank material. Training documentation has been developed as two tutorials were delivered with the software version. A brief description of the two tutorials woud be that Tutorial 1 refers to user preparation in order to get a first basis to enable the use of the simulation system which will furthermore allow to apply for Tutorial 2 where specific tailor blank simulation deep drawing is presented.The main results of the work performed during WP3 have been synthetically presented in deliverables TEC-3-01 (D05), TEC-3-05 (D06), with Quantech as contributor and TEC-3-04 (D07) with Quantech as main author.

Gr ap hic al

user interface windows

WORKPACKAGE 4 (WP4): INDUSTRIAL TECHNOLOGICAL ENHANCEMENTSWP4-1 Improvements in press tooling: investigated methods of overcoming practical industrial problems related to current TWB manufacture such as specialist off-set dies and to reduce the sheet twisting that occurs when TWBs are pressed. WP4-2 High-performance steels in tailor-blanks: different welding techniques that could be applied to these materials via numerical simulation have been examined so as to determine the practical limitations related to simulation usage.WP4-3 Aluminium tailor-blanks: similar examination of welding methods and limitations as those in WP4-2 have been made but in this case applied to aluminium blanks.The main results of the work performed during WP4 have been synthetically presented in deliverables TEC-4-01 (D08) and TEC-4-02 (D09) with Quantech as main author.

WORKPACKAGE 5 (WP5): INDUSTRIAL IMPLEMENTATION

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WP5-1 Installation and training of tailor-bank modelling (TL): adapted version of Stampack has been made available for the end-users and their engineers have been trained in the use of this new version via several training courses held at Quantech;WP5-2 Pilot studies of tailor-blank modelling for steel: software simulation predictions have been compared with industrial tests and industrial prototypes regarding conventional and high-performance steels with laser welding;WP5-3 Pilot studies of tailor-blank modelling for aluminium: similar to WP5-2 but addresses the usage of aluminium instead of steel. This task will dealt with DL and FSW welding and validated the numerical modelling possibilities;WP5-4 Adaptations to software (TL): the software development team in Quantech adapted, enhanced and bug-fixed the software according to feedback from the end-users. The end-users used similar lines of communication afforded to Quantech’s clients in order to centralise all feedback and track the subsequent actions;WP5-5 Industrial guidelines and evaluation of software effectiveness (TL): a quantitative evaluation of the software effectiveness in approaching the "right-first-time" process has been obtained by comparing the final software usage with the methods (and timing) prior to the project. Industrial guidelines for manufacturing tailor-blank components and for using simulation within the product and/or process design cycles were drawn up.The main results of the work performed during WP5 have been synthetically presented in deliverables TEC-5-01 (D10) and TEC-5-02 (D11) with Quantech as main author and TEC-5-03 (D12) with Quantech as main contributor.

Apart from the management and technical work Quantech also has been involved in WORKPACKAGE 6 (WP6): DISSEMINATION AND EXPLOITATIONWP6-1 Dissemination actions: personnel from Quantech visited clients and important companies in Japan, France, The Netherlands and Germany where the research work proposed in SIM-TWB project has been presented;WP6-2 Exploitation of results: specific actions related to the commercial exploitation, the in-house usage of the software, further academic and technical usage of the project results have been addressed by this task.In this WP Quantech contributed with information to deliverables DOC-6-01 (D13), DOC-6-02 (D14), DOC-6-03 (D15), DOC-6-04 (D116).

2.1.3 Links to other project work and other partnersQuantech has been involved in all workpackages sometimes as workpackage or task leader and sometimes as team member, but the general norm was that coordinated work has been developed in order to complete the majority of tasks and deliverables. Thus Quantech acted as PM for the whole project but also as workpackage leader for WP1, WP5 and WP7 and as task leader in WP1-1, WP1-2, WP1-3, WP1-4, WP3-3, WP5-1, WP5-4, WP5-5 and WP6-2. Based on contributions from the rest of the partners, Quantech lead the creation of 11 deliverables (D01, D02, D07, D08, D09, D10, D11, D12, D17, D18 and D19) and contributed with information and internal reports to 8 more deliverables as team member (D03, D04, D05, D06, D13, D14, D15 and D16)

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2.2 ComStampThis section overviews the project work carried out by Partner P02: ComStamp (Italy), an industrial SME partner of the project.

2.2.1 Com.Stamp work objectivesCom.Stamp as die manufacturers, has exploited the project software within their engineering teams in order to improve the quality of dies and manufacture.

2.2.2 Com.Stamp work done and results contributedCom.Stamp has given his contribution for the listed deliverables: - D02, ‘SME requirements, assessment and validation strategy’, indicating specific requirements

for the simulation system;- D08, ‘Proposed enhancements for press tooling for tailor-blanks’, indicating, in based on own

experience as die’s manufacture, the main problems and the process control;- D10, ‘Industrial process and simulation prediction comparisons for tailor-blanks’, from two

points of view:1. testing the new version of software Stampack 6.2.1, running the simulation of the same element changing the type of welding, the width of the weld’s bead, the influence of HAZ

2. running, with the new version of software Stampack 6.2.1, the simulation of the element Reinforcement B pillar, dies constructed by Com.Stamp.

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- D12, ‘Industrial guidelines for product/process design related to TWB indicating the limit of acceptability of welding according to the Italian standard.

2.2.3 Links to other project work and other partnersCom.Stamp has worked together PROSIT for all the life of the project. Since Com.Stamp uses the software Stampack from 6 years, it has collaborated with Quantech testing the new version of software and advising the results (output) of simulation.

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2.3 PrositThis section overviews the project work carried out by Partner P03: Prosit (Italy), an industrial SME partner in the project.

2.3.1 Prosit work objectivesProsit has improved own knowledge about the design and construction of tailor-blank presses.

2.3.2 Prosit work done and results contributedProsit has given his contribution for the listed deliverables: D02, ‘SME requirements, assessment and validation strategy’, indicating specific requirements for the simulation system;D08, ‘Proposed enhancements for press tooling for tailor-blanks’, indicating, in based on own experience as die’s maker, the main problems and the process control;D10, ‘Industrial process and simulation prediction comparisons for tailor-blanks’, from two points of view: testing the new version of software Stampack 6.2.1, running the simulation of the same element changing the type of welding, the width of the weld’s bead, the influence of HAZ; running, with the new version of software Stampack 6.2.1, the simulation of the element Reinforcement B pillar, dies projected by PROSIT.

2.3.3 Links to other project work and other partnersProsit has worked together with Com.Stamp for all the life of the project.

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2.4 Formpol-VABThis section overviews the project work carried out by Partner P04: Formpol-VAB (Poland), an industrial SME partner in the project.

2.4.1 Formpol-VAB work objectivesThe main objective set for Formpol-VAB was to provide steel material for testing purposes, according to specification and requirements outlined by all remaining partners in the project. Furthermore, Formpol-VAB was also expected to provide help and support in terms of any technical data related to steel material, as well as to provide machines and production facilities necessary to perform production trials with tailor welded blanks.

2.4.2 Formpol-VAB work done and results contributedFormpol-VAB provided initial support in selecting the most appropriate steel grades that could be successfully used for testing purposes, were frequently used in car body designs of various OEM manufacturers and yet could be easily retrieved from steel market. These carefully selected materials were shipped to other project contributors with the aim of performing material analysis, welding tests and other research activities. Material was prepared as blanks, cut from coil to shape and size specified by the aforementioned contributors to suit their specific needs. Material deliveries were accompanied by appropriate specifications and standards to explain chemical composition, physical parameters etc. Formpol-VAB offered access to its manufacturing machines (blanking line, mechanical 800T, 400T, 1000T, 315T press machines, 3D CMC measuring machines) and auxiliary equipment. Work force employed for the purpose of the SIM_TWB project included regular machine operators, as well as maintenance staff, quality assurance inspectors, technicians, engineering support and specialists from other fields, if they proved to be necessary. It was possible to execute in Formpol-VAB facilities elaborated try-outs and experiments on tailor welded blanks, using different machines with different settings and parameters. Results obtained during such tests have been carefully recorded and summarized in internal reports, which created a solid base of solid knowledge, exploited by all remaining partners in the project.

2.4.3 Links to other project work and other partnersFormpol-VAB utilized input information from basically all other project participants – this included theoretical background for try-outs and support in terms of stamping parameters. On the other hand, works performed by Formpol-VAB allowed other partners to accomplish welding try-outs and finally to consolidate results of stamping experiments in form of input parameters for SIM-TWB software.

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2.5 LasindustriaThis section overviews the project work carried out by Partner P05: Lasindustria (Portugal), an industrial SME partner in the project.

2.5.1 Lasindustria work objectivesTo become aware of the potential of laser welding as a service to include in the company’s portfolio

2.5.2 Lasindustria work done and results contributed

The work done by Lasindustria was mainly related with CO2 laser welding of tailor blanks and analysis of results achieved with the other lasers (Nd-YAG and fiber).

Fig. 2.5.1 - Jig used for the CO2 laser tests

Training the company personnel to perform laser welding, conduct experiments collaborate with IST on optimization of welding procedures were the tasks developed.

Analysis of the results and comparison with what was obtained with the other lasers was done in meetings at IST where vivid discussions were held.

Lasindustria is a SME with very limited financial resources to invest in new areas and innovation.The participation in the project has generated the necessary support for Lasindustria to take the step of starting to do laser welding as a job shop service to the market.

A new laser has been purchased; a new installation was rented and is now being refurbished to accommodate the laser equipments. This new location will start operating in October 2008 and is planned to work in laser welding in the near future.

2.5.3 Links to other project work and other partnersIt was the first time Lasindustria met most of the institutions who were partners in the SIM-TWB project. It was a very good experience for Lasindustria to collaborate in SIM-TWB.

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2.6 EWFThis section overviews the project work carried out by Partner P06: European Welding Federation (Portugal), a federation partner in the project.

2.6.1 EWF work objectivesEWF intention in participating in SIM-TWB project was to exploit new technology and knowledge arising from the project results, especially in dissemination activities directed at the welding sector that includes tailor-blank suppliers. Thought the several dissemination actions the EWF also intended to explore new sectors that can potentially use the project developments in an attempt to broaden their expertise and services.

2.6.2 EWF work done and results contributedThe support to the definition of a accurate model of the weld seam including aspects such as sheet alignment, type of welding, hear affected zone and sheet materials, was the major goal of EWF’s participation, as this is a topic of particular interest for the Welding community dealing with tailor-welded blanks. In this context, EWF focused the dissemination of the advances done within the project within the European welding community. Therefore, the activity of EWF in the SIM-TWB project can be summarized as follows:

WP1- Software and Experimental specificationsA brief presentation of the project was done to the EWF members aiming at collecting the impressions from European welding community. Also, EWF performed an analysis of existing software and collected feedback from EWF members.

WP2 – Experimental and Numerical characterizationAccording to the background knowledge of EWF network in welding techniques and processes, the EWF worked in close cooperation with ISQ in the definition of the welding procedures to be used. Aiming at collecting an European overview about welding techniques to be considered in the scope of the project, the EWF circulated a survey in EWF network about laser welding techniques in use and potential for future development. Also, the use of new types of lasers and friction stir welding for aluminium tailor blanks were topics addressed.

WP3 – Numerical development of modelsAn analysis of the models developed by IPPT and CIMNE was made.

WP4 – Industrial Technological enhancementsWithin this WP EWF participated in the identification of industrial problems associated with tailor-blanks manufacture, especially in what concerns practical limitations in industrial environments. Also, a survey on high performance materials and used welding processes was done.

WP5 – Industrial ImplementationAnalysis of Stampack (simulation software). Analysis of the Industrial guidelines for product/process design related to TWB.

WP6 – Dissemination and Exploitation Project related-info was published on both website and newsletter of EWF. The website is online (http://www.ewf.be/asp/show_project.asp?project=SIMTWB) and available to the general public. The bi-annual newsletter is sent to the EWF members – 29 National Welding Institutes, and to its national associates (among Research and Technology developers, SMEs and Individual contacts).

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http://www.ewf.be/asp/show_project.asp?project=SIMTWB


An initial project flyer has been created (SIM-TWB-leaflet-01.pdf). At a final stage of the project the project flyer was reformulated aiming at providing some technical advances achieved during the development of the project.

Project related info was distributed at the following events:- IIW (International Welding Institute) meetings in Paris, in January 2007. These meetings gathered representatives of 32 countries. The presentation of project related info aimed at raising awareness about SIM-TWB project.- IIW General Conference in Croatia, July 2007. This international conference had participants representing the manufacturing technology communities worldwide. Pamphlets were distributed on the Conference Social area and informal conversations about the project took place with some participants. - EWF distributed the project flyer at the IIW (International Welding Institute) meetings in Paris,in January 2008, which gather representatives of welding communities from 32 countries. - Distribution of Project related info at the 61th Annual Assembly and International Conference of - - the International Institute of Welding, Graz, Austria

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- Distribution of Project related info at the International Conference “Safety and Reliability of welded Components in Energy and Processing Industry”

Other dissemination activities done by EWF- Project related-info was published at the Magazine ‘Research Review’ (Issue 1 – March

2007) which was distributed as a supplement to the Parliament Magazine and has had an additional distribution to a named database of 5000 Research leaders. It was also distributed at a number of key research events covering a wide range of research topics

- Presentation of the project to Dr. Mauro Scasso, Istituto Italiano della Saldatura- Informal presentation and discussion of the project to interested persons participating at

ECONWELD meeting- Project presentation at International Conference – Moscow, Russia- Informal presentation of the project to representatives of AIMEN - Asociación de

Investigación Metalúrgica del Noroeste – Vigo, Spain- Informal presentation of the project to an industrial contact – Nottingham, UK- Presentation and distribution of project related info at the 'Welding Week – Antwerp,

Belgium'- Informal presentation and discussion of the project to interested persons participating at

LEADOUT meeting- Project informal presentation to interested contacts at ENDIEL Seminar- Project discussion with participants of ECONWELD meeting- Informal Presentation and Discussion about the project at the Contact Seminar 'New Basic

Skills for Employment"- Project Presentation to ISQ (Instituto de Soldadura e Qualidade) representatives- Informal presentation and discussion about the Project at the Meeting of new project –

Lifelong Learning Programme- Distribution of Project related info to Turkish representatives of Gazi University, Faculty of

Technical Education- Distribution of Project related info at the 61th Annual Assembly and International

Conference of - - the International Institute of Welding, Graz, Austria- Distribution of Project related info at the International Conference “Safety and Reliability of

welded Components in Energy and Processing Industry”

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WP7 - Management and ExploitationDuring the follow-up of the general development of the project the EWF always raised special attention to the exploitation conditions and requirements. It was decided that the Exploitation Plan will be maintained as initially forecasted, as it was agreed by all that Quantech would own the proprietary rights to the projects results but that all SME would have a right to negotiate usage rights (or user rights would be established for all).

2.6.3 Links to other project work and other partnersThe EWF, as industrial federation, followed the technical developments and industrial validation done by RTDs and SMEs, respectively. Therefore, taking into consideration its major activity in dissemination, the EWF had to closely follow the development of the project, as it was mentioned in the item 2.6.2 Partner work done and results contributed.

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2.7 CIMNEThis section overviews the project work carried out by Partner P07: CIMNE (Spain), a RTD partner in the project.

2.7.1 CIMNE work objectivesWP1: Software & experimental specifications

Contribute to fully define the mathematical models to be used. Contribute to define the experimental work to be carried out:

o Tensile tests with TWB and LDH tests with TWB. Contribute to fully define the industrial validation strategy

WP2. Experimental & numerical characterisation Contribute to characterise the weld seam models for sheets:

o Study of alignment cases.o Thermal mechanical weld line and HAZ material characterization.o Definition of welding parameters.

WP3. Numerical development of models Coordinate the weld seam numerical models develop:

o Finite element to consider weld material constitutive effects.o Algorithms to improve the CPU times.

Contribute to adapt the user interface for tailor-blank modelling.WP5. Industrial implementation

Contribute to define the industrial guidelines for use the software (meshing, density scale, characterization of material criteria, others).

Validate the software functionality:o Deep drawing tests in B-Pillar Benchmark for steel and aluminium alloy.

WP6. Dissemination and exploitation Contribute to consortium Agreement. Contribute to dissemination activities.

WP7. Project management Contribute to coordination of the project from the administrative and technical aspects. To

coordinate with other related projects.

2.7.2 CIMNE work done and results contributed

WP1-1 Specification for tailor-blank modelling Full mathematical definitions of the model used for the weld seam have been defined. This includes the sheet alignment for welding line and the HAZ. A macro-mechanical model based on experimental microstructure observations and welding simulations (inverse analysis) was included. The definition of the program structure, input parameters, user interface and database requirements were defined. Oriented user definition of the tailor-blanks facilities were defined too.WP1-2 Specification for experimental and numerical weld characterisation The experimental work required for characterize the welding processes and develop the constitutive model for the weld seam and HAZ has been defined. Experiments on welding, sheet forming (tensile tests, bending tests, Bulge tests and LDH tests), including microstructure observations, were selected and done. These tests had been required to characterization of weld line and HAZ and the numerical models. The use of simulations with TWB are (and will be) an additional aid to characterise the welding techniques and know the parameters influence as has been demonstrated in this project.

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WP2-4 FEM studies to characterise welding The Finite Element Method (FEM) has been used as an additional aid to study the complex thermal-mechanical-metallurgical interaction during welding. These inverses analysis help to characterise the welding processes. Once the experiments of WP2.1-2.2 were verified and characterised the simulation studies were used to expand the characterisation databases for all the parameters required [4]. In this way the costs of parameter studies and physical experimentation have been reduced.

WP3-2 Development of complete weld seam behaviour modelThe complete software of weld seam behaviour was developed and programmed. The software includes geometrical effects such as sheet alignments (different sheet thicknesses welding top-top, bottom-bottom, centre-centre, etc.) that produce local bending and torsion effects along the weld

and around. The weld material constitutive effects (virgin material, HAZ, transition zone, etc.) are considered too (see WP3-1 and [5]). Finite elements with efficient integration algorithms were required to the mesh along weld seam because extra fine mesh wasn’t possible to avoid. A series of preliminary tests were done. To get initial verifications of the model simulations of experimental work on the blanks were done. The algorithms to improve the CPU times demonstrated a high level of efficiency (CPU time < 20hs in B-pillar benchmark).

WP3-3 Adaptation of user-interface for tailor-blank modelling To define the TWB and the characteristics of weld-line a specific adaptation of Stampack interface have been done. The interface is oriented to easy and logical interface use in industry. The user has to define the different zones and assign different materials depending in the heat treatment suffered. The basic idea is that the user defines the different blank zones as well as the weld-seam which will be a geometrical surface with material properties (tempered or annealed), all as entities of

the complete blank. The facilities of system help to user the generation of material zones, different finite element types, etc., without any intervention, or even knowledge, from the user.

WP5-1 Installation and training of tailor-blank modelling CIMNE carried out an intensive benchmark tests (LDH deep drawing test, B-pillar industrial process). These tests were previous activities to installation at the end-users. Tested Stampack version was installed by Quantech at the end-users finally. Their engineers have been trained in new Stampack version in Quantech. They are

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Figure 3: STL mesh* in Stampack (* provided by PS)

Figure 2: Blank’s mesh and detail of WL, HAZ and transition zones.

Figure 1: Laser welding in simulación and Temp vs. Distance to WL in sheet welding.


responsible of user-interface aspects and future usage of system. Continuous support will be available via the Quantech Training Centre.WP5-4 Adaptations to software Some problems during industrial validations with the software and some new ideas were formed, the development team adapted, enhanced and bug-fixed the software according to feedback from the end-users. The end-users also have been used the communication lines offered by Quantech to their clients in order to centralise all feedback. The corresponding corrective actions were done by Quantech. CIMNE collaborates in detection, management and correction of possible errors in kernel calculus module at the present and the future.WP5-5 Industrial guidelines and evaluation of software effectiveness The Efficiency of the software has been evaluated by:- Comparison of the final software version with the initial software (prior to the project).- Comparison of the final software usage effects in industrial organizations. The actual impact in design methodology and timing in relation with prior them to the project has been analyzed.Industrial guidelines for use the software has been explained (mesh, density scale criteria, characterization of materials).

WP6-1 Dissemination actions The next dissemination actions have been done by CIMNE: Publication and exposition of a paper [2] and technical contributions to publications done by EWF. WP6-2 Exploitation of resultsSpecific actions related to the in-house usage of the software, further academic and technical

usage of the project results has been done in this task. Details and potential uses are described in related deliverables.

WP7-1 Project Management The main contribution of CIMNE to Project Management was the Research Coordination and leading the WP3-2. CIMNE was appointed with the responsibility to follow up and asses the development of the RTD works. The preparation of deliverable D06 - Weld seam numerical behaviour model and weld macroscopic constitutive model with initial verification –

was coordinated by CIMNE. CIMNE had links with others RTD partners and industrial partners during the research works, promoting coordinated activities and discussions about specific technical aspects and final required capacities.

2.7.3 Links to other project work and other partnersThe links with others partners to each work task are described in the section 2.7.1. The level of collaboration and cooperation was in function of nature of each work.

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Figure 5: FLC simulation results.

Figure 4: FLC experimental results (provided by PS partner)


IPPT-PANThis section overviews the project work carried out by Partner P08: IPPT-PAN (Poland), an RTD partner in the project.

2.7.4 IPPT-PAN work objectivesThe main objectives of the work done by IPPT PAN within the project were the following: Development of thermo-mechano-metalurgical model allowing simulation of blank welding. Development of the macroscopic model of the tailor welded blank providing possibilities of

accurate simulation of tailor-blank forming. Numerical implementation of the above models. Development of methodology to determine the model parameters. Performing basic numerical tests.

2.7.5 IPPT-PAN work done and results contributed Mechanical properties and formability of tailor welded blanks have been characterized from the

point of view of modelling needs. Factors influencing the deformation performance of the tailor welded blanks have been identified. The basic factor influencing the formability of tailor welded blanks is hardening of the weld joint and heat-affected zone during welding process. This reduces formability in the area of weld and it has been identified as the basic factor that should be taken into account in the tailored blank model.

Computational macroscopic model of tailor welded blank has been developed and implemented in the computer code Stampack. The model allows two stage modelling, with welding process analysed in the first stage and forming simulation in the second stage. Alternatively one-stage forming simulation can be performed only using the macroscopic deformation model of TWB. The macroscopic deformation model can be constituted by a combination of continuum, shell and/or truss elements. The user has the possibility to select a suitable option considering the accuracy needs and efficiency requirements. Theoretical formulation of the numerical model has been described in the deliverable D05: Weld macroscopic constitutive model − theory.

The deliverable contains also proposed methodology to determine geometrical parameters and mechanical properties for the weld zone. Weld and heat affected zones properties can be determined by experimental procedures or to some extent by numerical simulation of welding process.

Basic validation of the model has been doe by IPPT PAN. A number of test examples have been analysed. Verification tests have shown that numerical model correctly represents complex deformation of TWBs

Following the specification of experimental work required for numerical models IPPT performed selected experimental tests of the tailor welded blanks:− Metallographic observations− Tensile tests (weld properties can be extracted) − Microhardness tests− Indentation testsIPPT analysed the results of experiments from the point of view of numerical model validation.

Using the experimental results and proposed methodology the model parameters have been determined for selected TWB. The following methods have been used to determine the extension and mechanical parameters of the weld and heat affected zone:

− Metallographic observations – provide information about the extension of the fusion and heat affected zones, as well as phase composition in these zones.

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− Uniaxial tension test – this test gives stress-strain relationships for the parent material and the weld.

− Micro hardness test – these tests provide information about the distribution of hardness in the tailor weld blank. Increased values of hardness indicate the extension of the weld zone (fusion and heat affected zones). The relationship between hardness and strength of the material allowed us to determine strength parameters of the weld zone.

− Indentation tests with inverse numerical analysis. Mechanical properties of both parent material and weld zone have been determined by the inverse analysis. A numerical model has been created for the indentation test and the indentation has been analysed fitting the results of indentation tests.

Using the thermo-mechano-metallurgical model simulation of laser welding process of different joints of tailor welded blanks has been carried out. Welding of tailor welded blanks composed of blanks of the same and different thicknesses has been analysed. As a result of the simulation the following results have been obtained:− temperature distribution and evolution (Fig. 1a),− extensions of the fusion and heat affected zones (Fig. 1a),− phase composition in the fusion and heat affected zones,− residual stresses in the weld zone,− mechanical properties in the weld zone (this is an auxiliary source of knowledge about the

mechanical characteristics of the weld).Results of the simulation have been compared with experimental data (Fig. 1). A good agreement has been found.Sensitivity analyses have been carried out – influence of process parameters (welding velocity, beam power and diameter) has been studied, which is a valuable help in the welding process optimization

Guidelines for modelling of industrial problems have been proposed

2.7.6 Links to other project work and other partners Knowledge about the welding process was obtained from IST and Lasindustria Experimental procedures have been defined with the help of Politechnika Śląska Numerical model has been implemented in the Stampack software with the help of Quantech IPPT PAN collaborated with CIMNE in model verification and validation Collaboration with Quantech in model and implementation adjustment.

a) b)Fig. 2.8.1. Comparison of numerical results with micrographical observations – extension of the fusion and heat affected zones: a) numerical results, b) micrographical observations.

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2.8 PSThis section overviews the project work carried out by Partner P09: Politechnika Slaska (Poland), a RTD partner in the project.

2.8.1 PS work objectivesLooking on strategic objects of SIM-TWB project, especially on:

improving concurrent engineering practises in TWB manufacturing and tools designing, providing accurate simulation for the prediction of TWB behaviour, improving welding technology, reduction vehicle weight.

PS has defined method of TWB drawability evaluation based on laboratory tests with seam weld behaviour analysis in according to forming limit curves of joined sheets. Laboratory tests and hardness measurements on cross section of weld area have helped to define 5-zones model of TWB and applied this model to accurate simulation. Laboratory tests for TWBs joined of different materials and using different welding techniques, allowed to choose proper joining techniques for steel materials and aluminium alloys. Industrial test of stamping B-pillar from TWBs obtain 16% weight reduction for designed blank. It corresponds with planed vehicle weight reduction.

2.8.2 PS work done and results contributedPS has defined possibility of experimental work on sheet blanks and Tailor Welded Blanks (TWB). Steels and aluminium sheets for tests supplied Formpol-VAB, IST and CIMNE. TWBs have prepared by IST and PS Subcontractor – Polish Welding Centre of Excellence (PWCoE). After materials for testing had been defined, sheet alignment of TWBs has set.

Drawability of tailored blanks depends largely on the characteristics of component blanks and the quality of a weld. Therefore it is difficult to determine the drawability of that kind of material taking into account all the possible types of blank tailoring. In general, this problem concerns elaborating the method of analyzing the flow of nonuniform material of tailored blank in the drawing processes which feature variability of geometry, stress and strain in the area of forming. This is particularly difficult if the characteristics of component blanks are the only criteria. The mode of blank flow in the weld zone and in the neighbouring zones is of a nonuniform nature which appears to be the main problem in designing the drawing process. This is due to diversification of strength of the tailored blanks and hardening of the weld. The nonuniform mode of blank flow may result in the local change of strain scheme and in the change of the position of critical areas of a drawpiece, i.e. the potential areas of the loss of strain stability which in turn can result in cracking of the blank. These changes are difficult to predict and therefore the suggested solution to that problem is the application of computer simulation techniques in the designed process.

Estimation of the formability of a tailored blank is not possible taking into account only the formability of the component sheets, without considering the shape of the drawn part as well as the location and orientation of the weld line with respect to directions of principal stresses in the blank. The relationship between the formability of the base material and the formability of the weld zone could be found. The best solution is model which parameters can be determined from the characteristics of the component sheets and properties of the welded zone.

The five-zone model of Tailor Welded Blank should be used in numerical simulation. This model makes it possible to describe with great precision the characteristics of laser welded blanks and it also enables to simulate the drawing process precisely enough for industrial application. The simplified three-zone model can be used for the simulation of the process of drawing of tailored

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blanks in such cases where the precise local strain distribution in the neighbouring zones of the weld core (which are the zones of heat effect) is not of a great significance. The suggested model of tailored blanks allows determining the parameters of the model taking into account the orientation of rolling direction of component blanks in relation to the direction of weld line. This allows considering the anisotropic characteristics of tailored blanks in calculations which simulate the drawing process.

PS has done experimental work (WP2, and WP3) on sheet blanks chosen for testing of drawability and defined their mechanical properties, the same test had TWBs of defined sheet alignment. The hardness measurements done on cross sections of weld areas, allowed defining numbers of zones in typical weld area. It obtain 5-zones model, consists of 2 zones of basic sheets materials(BSM), 2 zones of hot affection (HAZ) and 1 zone of the seam weld (W). The major work in preparing TWBs model, the best for simulation, IPPT-PAN has done. Looking on drawability of welds occurred that the best joining techniques for sheets of steel (typical drawability and advanced high strength steels) is laser welding using CO2 laser or Nd:YAG laser, but for aluminium alloys the best solution is to use friction stir welding (FSW) method.

PS realized industrial application of TWBs (WP4 and WP5) base on earlier industrial experience on TWBs. Industrial tests have been provided to manufacture drawpiece of B-pillar from accurate designed TWBs. The major aim of designed TWBs was to reduce thickness of sheet (in the end to reduce the weight of blank – see exemplary figure) and execute it in proper area of the blank. Tests of welding techniques and study on proper laser welding parameters made by IST and PWCoE, allowed to execute good welds, it means welds of good drawability properties and accurate for stamping processes.

Blank for B-pillar weightTypical blank (2mm thick)

11,50 kg

TWB (2mm+1,2mm+2,mm thicknesses)

9,61 kg

Weight reduction result (16%) 1,89 kg

The data consists of basic properties, drawability properties and FLCs coordinate for testing and simulated materials PS has delivered. All partners could use it. PS has prepared numerical model of B-pillar geometry and CIMNE, based on it, has done simulation of stamping using Stampack software for this drawpiece.

2.8.3 Links to other project work and other partnersThe 12 Month Meeting (12MM) took place on 21 September 2007 in Katowice, Poland. PS was the organizer.

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Steels and aluminium sheets for tests supplied Formpol-VAB, IST and CIMNE. TWBs have prepared by IST and PS Subcontractor – Polish Welding Centre of Excellence (PWCoE). Materials have been tested by PS, IST and IPPT-PAN. Partners have been exchanged results during whole project period. Results of testing are accessible for all project Partners, especially as data for Stampack.

PS cooperate with CIMNE and ComStamp preparing guidelines for industrial test of TWBs. Formpol-VAB made accessible for PS their production line, dies and sheets for blanks and TWBs to realize industrial tests planed in SIM-TWB project.

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2.9 ISTThis section overviews the project work carried out by Partner P10: Instituto Superior Técnico (Portugal), a RTD partner in the project.

2.9.1 Partner work objectivesIST participated in the project SIM-TWB to bring to the consortium expertise in welding techniques for tailor blanks and to develop innovative techniques. The innovation gathered in the project, namely the use of Fiber laser, Nd-YAG laser and FSW (Friction Stir welding) contributed to make the IST Welding and Joining Group more knowledgeable and more competitive.

2.9.2 Partner work done and results contributedThe work of IST focused on an extensive experimental plan for comparing welding techniques for tailor blanks. This included arc welding, due the interest of one SME in the consortium that was producing tailor arc welded blanks, laser welding and friction stir welding.

The welding processes used were:i) Arc welding

- TIG (conventional process widely used due to low cost)- CMT (innovative low heat input variant of MIG/MAG welding with better potential than

conventional MIG/MAG for tailor blank welding)ii) Laser welding

CO2 laserNd- YAG laserFibre laser

iii) Solid state welding- Friction stir welding

The SMEs in the partnership choose the materials that they found were more relevantly used in tailor blanks – DC04 steel and Al alloys and the thickness, from 0.7mm to 1,2mmm. The materials and processes used are summarised bellow.

MIG and TIG are low cost welding processes, thus despite the fact that the tailor blank welds obtained using these two processes present more formability problems than with more advanced welding techniques, arc welding might still be interesting to consider for applications where the quality levels achieved are acceptable. These two processes also present a low welding speed when

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compared to Laser Welding; however the welding equipments necessary for TIG or MIG are low-priced when compared with the equipments necessary for Laser Welding. Based on this conclusion and the values for the welding speeds presented in this work is up to the company to decide if it is better to have four welding lines using TIG or MIG or just one using Laser. As alternative to MIG and TIG a new welding process was experimented, the CMT welding process has low heat input and a higher productivity when compared to MIG. These advantages are very well adapted to TWBs. The results show that TIG welding has a lower heat input combined with a lower welding speed for TWBs when compared to the values obtained with CMT.

Considering the results obtained for the tensile and bending tests on the steel DC 04 samples welded with TIG and CMT, it is possible to conclude that the weld does not influence in a negative way the properties of the TWB, as the TWBs crack on the thinner plate in the parent material away from the HAZ.

It is also possible to conclude that the properties and composition of the steels are very important for TWB and that the welding parameters vary depending on the steel used.

However when comparing productivity the laser welding equipments used on steel DC 04 are in front of any other welding process tried in this work. In terms of quality the results are similar to the ones obtained for TIG and CMT with the advantage that, due to the lower heat input laser welding presents, the plates present an insignificant deformation. Combining this with the fact that plates laser welded do not need any post-welding operations, differing from TIG and CMT welded plates, the best welding equipment for TWBs is laser welding. The question at this point is which laser to choose.

Fig 2.10.1 – Nd-YAG laser and Fiber laser equipments used

The three lasers used, Fiber, Nd:YAG and CO2 all present advantages of one way or another, however the Fiber laser is the one that shows better overall performance. Not only it is the one where the highest welding speeds were obtained but also it is the one that presents the lowest cost per hour.

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Fig. 2.10.2 – FSW (friction stir welding) equipment used

For the Aluminium alloys the choice was easy to make, mainly because of the results obtained with the CO2 laser. Using this laser it was not possible to weld two of the three combinations, on the other hand FSW did not present any kind of problem in welding the Aluminium alloys. It is true that FSW does not present a very high productivity but this lack o productivity is balanced by the quality of the process.

2.9.3 Links to other project work and other partnersIST had not been in any project with the organizations involved in SIM-TWB but the participation in this project has generated good work relationships. It is expected that this collaboration will continue in future projects for which ideas have already been discussed.

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3. Final project outcome and ConclusionsThe main project results may be summarised as follows:- software module for the simulation of tailor-blank forming processes;- characteristics database and know-how of welding techniques and materials;- experimental know-how of welding techniques and characterisation;- industrial know-how for improved tailor-blank forming;- industrial know-how for usage of high-performance materials in tailor-blanks. The useable software modules all the SMEs are exploiting directly by installing and utilising in-house. Practical guidelines resulted from the project relating to optimum tool design and the use of simulation for the utilization of tailor-blanks. The SIM-TWB project objective has been achieved to combine new industrial guidelines and simulation development to provide the following direct benefits to the SMEs:• effective use of tailor-blanks with curved weld seams,• improved prediction of weld seam behaviour (twisting in die, rupture adjacent to heated zone, etc.),• improved understanding and characterisation of laser and friction stir welding techniques,• improved die design to control twisting and movement of weld seam,• reduced trial-and-error and manufactured prototypes,• confident use of high-performance steels and aluminium in tailor-blanks,• improved product/process design methodology using CAD-CAE and a closer working relationship between clients and providers,• reduced overall cost of manufacture.

The SMEs in this project have been representative of the sheet pressing sector: die manufacturers, component suppliers, process design engineers and software engineering and had a direct interest in the successful outcome of the SIM-TWB project. All agreed that new technology introduced at the SME supplier level will improve the competitiveness of the sector as a whole (assuming the EC average that more than 99% of the sector are SMEs). The best way is via the use of adequate simulation tools now that computer advances have provided the hardware and the supply of engineers is constant (even if they need to be attracted to this market). Adequate software means taking into account all the process parameters, accurate, relatively fast and very user-friendly software in order to reduce engineer time which is much more expensive than CPU cost.

Besides the obvious benefits for the final product and the SMEs there are additional benefits. Simulation tools such as these enhance the collaboration between suppliers and their clients since the tier suppliers automatically become more involved in the actual design process and this in turn enhances future trans-national cooperation. The improvement of the whole sector in terms of knowledge gain and use of knowledge-based technologies will also be improved.

The development of numerical algorithms and improved manufacturing techniques and the validation thereof as planned and performed within the SIM-TWB project required the combination of engineering, mathematics, programming, material and experimental skills that are extremely difficult to obtain on a local level in almost any EC country. The SMEs all share similar problems (together with other companies on an European level) and the project included 1 non-SME organisations (an association) that have a special interest in the project results who helped guiding the project progress. The project thus united 10 partners from 4 EC countries (Spain, Poland, Portugal and Italy) with complimentary expertise in development of finite element software for sheet stamping (CIMNE), development of material modelling and characterisation (IPPT-PAN), experimental techniques for sheet forming (PS), experimental/industrial techniques for welding processes (IST,

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Lasindustria), industrial experience in die and part manufacture (ComStamp, VAB), process design and solution providers (Prosit), dissemination at a European level of welding related results (EWF), customisation and marketing of metal forming software (Quantech).

Improving the CAE simulation and the concurrent engineering concept related to tailor-blank design and manufacture will have the following direct impacts for the SMEs:• enhanced design prediction methodology rather than correction of errors further down the line ("prediction is better than cure") based on accurate CAE simulation,• effective design and manufacture of tailor-blanks with curved weld seams allowing further weight reductions for same or better performance and the introduction of tailor-blanks where they were notconsidered previously,• improved die design to control twisting and movement of weld seam,• use of high-performance materials such as TRIP steels or aluminium in tailor-blanks• potential new applications in electro-domestic and aeronautics/aerospace sectors by applying thesetechniques to stainless steel pressings,• improved knowledge of new welding techniques such as friction stir welding,• optimised product and process design due to closer working relationship with client or provider using concurrent engineering,• reduced overall cost of manufacture,• reduced time-to-market.

Direct cost benefits for the SMEs will derive mostly from the ability to gain insight and understand the manufacturing process by an accurate simulation beforehand. The table below provides a conservative cost comparison for a single stage press die, assuming that (a) the die design is modified during trails and not completely re-done (as often happens), (b) the modifications can be carried out with relative ease and (c) the simulation does not provide a 100% solution but provides all the trends and potential difficulties.

This creates a saving of €120.000 for the die if 2 trails are required or a saving of €170.000 if the process is really "right-first-time". A typical SME die manufacturer or designer such as those in this project usually deal with about 15 to 20 parts (at least) per year of which 2 to 4 could be tailor blanks (depending on their size and expertise). This could imply a saving of at least €290.000 annually and possibly €1.000.000 for 1 company if they made the same savings on about half of their total production. A simple calculation shows that the cost of the SIM-TWB project will be rapidly recovered in this way.

Time saving benefits may be even more important for SMEs as the automotive companies push to reduce the design to production time to less than 24 months (usual timescales are now about 36 months). By using simulation the SMEs estimate that they can reduce the average time to produce a working die by at least 30-40%. Die design and manufacture if often the bottleneck in the overall car design-production cycle and in some particular cases it has even been recorded that simulation has reduced die production by as much as 13 months[1]. For a typical SME this is essential business strategy in order to remain competitive.

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Outside of the automotive sector the SIM-TWB technology and software can be applied to the aeronautics, aerospace, defence and nuclear sectors. These high-technology sectors are seeking methodologies to reduce weight, improve performance, quality and safety and the welding and tailor blank technologies developed here will suit many applications where weight can easily be reduced by using a simple tailor-blank of differing thicknesses with good welding technology.

European dimensionThe SIM-TWB project will contribute directly to the critical and increasing need of producing sheet metal products with higher quality properties in the European metal forming industry. This has a direct affect on the automobile sector, working more and more at a totally European level, who utilise about 78% of all stamped sheet metal in Europe. Moreover, the introduction of CAE simulation into the product/process design phases has been proved to have huge benefits in forging collaboration between clients and suppliers. The industry as a whole has not yet embraced the use of high-performance steels and aluminium in tailor-blank applications since much fundamental process knowledge is lacking.

The SIM-TWB project thus created potential for Technology Transfer at all levels of industry and to all countries within the EU and Associated States. The combination of partners from Spain, Poland, Portugal and Italy represents the full spectrum of technically advanced and less advanced regions and the nature of this partnership will enhance the technology transfer within the group. Now that reasonable results are available a series of dissemination activities are being arranged in order to promote the technology transfer among the various regions represented within the project.

The Stampack pricing strategy is particularly advantageous for Associated States and future commercial marketing and sales collaboration between the consortium partners (or other companies in the regions) have high potential. In this way permanent links will be created throughout Europe and the Associated States.

Contribution to standardsThe project does not contributed to any standardization or regulation norms but provided practical guidelines and training possibilities for the use of simulation within the product/process design stages related to the utilization of tailor-blanks. These industrial guidelines and simulation development will provide direct benefits to the SMEs.

Contribution to policy developmentsThe impacts for the SMEs listed above in utilising tailor-welded blanks (TWBs) translate directly into global benefits for the automotive industry, with direct positive environmental and societal consequences [2,3]:• up to 25% reduction in weight when replacing about 50% of the body weight by tailor-welded blanks,• improved structural integrity and safety for less material weight (overall strength can be improved by 80%),• reduced fuel consumption and emissions directly proportional to the car weight

Furthermore, simulation is a trial and error prototyping process, but carried out on a computer and not on the shop floor. This produces enormous savings in time, labour and materials, but also has the associated positive psychological effect on the design team and workforce since problems are predicted and corrected before they are found after tooling has been done. Too often these effects on the workforce are not taken into account when it is well known that a positive working attitude

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will benefit the company, country and Europe in many ways that are largely unseen and difficult to quantify.

Human interaction with dangerous stamping presses is reduced too, improving safety in the workplace. Simulation replaces much of the physical prototyping and creates a more stable and repetitive process that reduces the human interaction with the presses thereby improving the safety for metal forming workers.

Reductions in scrap metal and the use of lubricating oils due to less prototyping, optimised parts and processes, less machining and thermal treatment operations to rectify problems are all anticipated benefits of the use of virtual prototyping and simulation technologies - these lead to more environmentally friendly production processes and practises.

The development of the better simulation technology will help introduce technical expertise and status in the metal forming industry leading to a more knowledge-based industrial sector and enabling the sector to incorporate new advances in virtual production, supply chain and life-cycle management. The application of simulation contributes to the attractiveness of the work in the metal forming sector and requires recruiting skilled engineers to be trained in using this technology. Increased scope and opportunity in the job market is provided due to software advances since it is possible to utilise engineers that do not have formal university training or only a basic engineering degree.

The use of simulation encourages the participation of women in the engineering sector that continues to be male dominated thus ensuring full equality in terms of career development and advancement. Equality is ensured since all jobs in numerical simulation, product and process design can be done by women.

4. FutureThe innovative aspects within the SIM-TWB project will provide excellent exploitation opportunities for all the partners and have the potential to open new areas of R+D. General exploitation agreements will form part of the Consortium Agreement and will define aspects related to future commercial agreements, confidentiality, software usage and special conditions and collaborations.

Quantech will market and sell the Stampack system with the new tailor-blank modelling among metal forming companies within the automotive sector in Europe and world-wide, using their distribution network. Stampack will gain in reputation and Quantech will promote possible advantages in other sectors such as aeronautics as well. Quantech has already done work in the aeronautics sector related to the manufacture of single components where previously there were many parts riveted or joined together - welding could play a vital part for these components. Future development agreements will be drawn up between Quantech and interested RTD Performers in order to enable continued collaboration, development and software evolution. For future software improvements the industrial know-how achieved may be particularly important to Quantech, but collaboration is required since Quantech do not have the means to carry out experimental testing. A technology watch will be maintained (this will include other partners) in the future to seek new market opportunities and new applications requiring future R&D projects. Quantech together with EWF will develop educational/training courses, both presential and distance related to simulation of tailor-blank components covering forming and welding technology, process engineering, etc.

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ComStamp and VAB as die manufacturers and sheet stamping suppliers will exploit the project software within their engineering teams in order to reduce their physical prototyping and improve the quality of their dies and manufacture. By implementing the new/improved technological know-how into their product/process design procedures ComStamp will be able to improve their client's manufacturing procedures thereby improving overall quality and component technology. VAB will, as a sheet stamping supplier, directly improve their press technology and offer new quality tailor-blank components. Following the successful completion of the project these companies are prepared to act as reference sites for future dissemination activities.

Prosit will utilise the project software and know-how to improve their technological and product/process design services in-house with respect to tailor-blank manufacture. This will improve their offer for the design and construction of tailor-blank presses with the related technology to their current clients in the sector and enable them to gain new. Prosit wish to co-operate in the marketing and sale of the resulting Stampack software containing the result R1 and may therefore form part of the distributor network.

Lasindustria will utilise the project software and know-how to improve their technological and product/process design services in-house with respect to welding and the provision of the initial sheets/blanks for tailor-blank manufacture. This will improve their offer of high technology components and they are particularly interested in the use of high-performance materials for the construction of tailor-blank components.

EWF will exploit the new technology and knowledge in dissemination and training actions directed at the welding sector that includes tailor-blank suppliers. EWF will, together with Quantech, develop educational/training courses for both presential and distance learning related to these results and may act as a promoter of the software. They will also explore new sectors that can potentially use the project developments in an attempt to broaden their expertise and services. Furthermore they will seek future projects to continue the development of the technology introducing certain SIM-TWB partners into new consortiums for these new projects.

The RTD Performers, CIMNE, IPPT-PAN, PS and IST will each continue with their R&D lines after the end of the project but will be able to exploit the newfound knowledge and experience gained during this project. Each RTD Performer will maintain interest in the results that they helped produce and may be contracted by the SME Proposers in the future to carry out related development or experimental work with an aim to further improve the technologies developed. All RTD Performers will support the dissemination actions during and after the project and their commitment to continue collaborating with the SMEs after the project will probably lead to further R+D activities and projects. This will be particularly important for the continuation of the software development and the welding technology. A technology watch will be maintained (Quantech and EWF will also participate) in the future to seek new opportunities for R&D projects that will maintain the momentum of this work in a seemingly never-ending quest for technological improvements.

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5. References

[1] "Digital die manufacturing in Automotive stamping", E.J. Kim and J.S. Hwang, Hyundai Motor Co., presented at Numisheet 2002, Korea,October 2002

[2] ULSAB (Ultra Light Steel Auto Body) Consortium. Members included 35 steel producers in 18 countries. Launched in 1994 and completed in1998. http://www.ulsab.org

[3] “Tailor Welded Blank Design and Manufacturing Manual”, Auto/Steel Partnership (A/SP), Chairman: Syd Melbourne, July 1995.

[4] “Accurate simulation of Tailored-Welded-Blanks to reduce the process design time for the sheet pressing industry”, A. Ferriz, O. Fruitos, A. Maymó, 4th GiD conference, Ibiza, Spain, May 2008

[5] “Weld seam numerical behaviour model and weld macroscopic constitutive model with initial verification”, O.Fruitos, A. Ferriz, A Maymó, E. Oñate IT CIMNE s/n, Barcelona, Spain, 2008.

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