Forming and laserwelding of Vanes

Purpose and goal

The purpose was to develop methodology for sequential simulation of residual stresses in a hydroformed and laserwelded vane. The project´s objectives have been met and has created new knowledge about sequential simulation of preforming, hydroforming and laser welding, presented material data for welding simulation in Haynes 282, investigated possibilities with fracture criteria in Autoform and evaluated a new way of shaping the vane around a rubber spool.

Expected results and effects

The project has identified a several techniques for simulation of aggregated residual stresses after preforming, hydroforming and laser welding. The project has initiated methodology for FE-simulation of preforming and laser welding, evaluated possibilities with an innovative forming technique where the guide rail is formed around an inner rubber pulley. The project has led to a new approved project within the Lighter member program, which will be carried out during the spring of 2019 together with RISE IVF and HDL.

Planned approach and implementation

Tests with simulation of preforming, hydroforming and laser welding on a test case of a Vane have been carried out by RISE IVF in collaboration with HDL, Jobro and Brogrens. The simulation tests have been performed in LS-Dyna and Autoform. With the support of JMAT Pro, GKN has produced material data for welding simulation. The work was initiated via a start meeting at Jobro and has been regularly reported with the support of web-based work meetings.