Simulation and Reliability Analysis of Laser-Welded Blanks after Metal Surface Finishing Process

Currently there is a huge competition amongst the OEMs and manufacturers in the auto industry to reduce the weight of the car. A few design modifications or use of different size and grades of materials solves this problem greatly. This paper focuses upon the metal finishing process of Laser Welded Blanks (LWB) with simulation and reliability as well as new process development. These blanks are of same gauge-same gauge or different gauge-different gauge materials. The main aim of this process was to remove the visible portion of the weld on the blank, so that it can be used as a body-outer. A new process was developed using expert knowledge and automated machinery tools. A simulation model was developed to compare with the actual developed method and to detect the bottlenecks and optimize the process. Reliability was a major concern during laser-welded blank operations. The paper addresses prediction of the amount of material removed based on the failed parts and visibility of the weld. This approach could provide competitiveness in the weight of the car which is directly related to fuel efficient and long term survival.