Advance Manufacturing Method to Meet Various Strength Requirements in CABIN Structure 2013-01-2902

CABIN design is continuously undergoing a huge change for reasons of customer comfort on for meeting regulatory requirement. Consequently the strategic design process will not only consider need for high strength structures but a pragmatic research based approach utilizing the latest technology. Though cab structure is built by a sheet metal blank as per the required dimensions, some locations encounter great amounts of stress and must be designed to withstand the same in a durable way. A possible simpler practice would be to add reinforcements in the high stress area or use high strength material for the entire part. However in this approach weight and cost of the component will be increased.

As the weight of the Cabin, vehicle increases this will impact fuel efficiency. Attempts have been taken like using composite materials.

This paper deals with the manufacturing of Cab parts like Floor and Floor structure by having tailor made blank using Laser weld technology called Tailor Welded blanks. TWB are metallic sheets made from different strengths, materials and/or thickness pre-welded together before forming into the final components of geometry. By combining various sheets into a welded blank, engineers are able to ‘tailor’ the blanks so that the properties are located precisely where they are needed. Thus the cost effective, low weight components are produced. Tailor welded blanks for advanced manufacturing examines the manufacturing for tailor welded blanks and explores their current and potential future applications. TWB is a complete solution with lower metal scrap, high strength and better aesthetics⁽¹⁾. TWB can be subsequently be deep drawn or stamped. To find the high stress area FEA tool has been used. Longitudinal member and Floor panel are manufactured using TWB, no constrains observed during/subsequent to manufacturing and component level validation. The results satisfy the quality requirements. The developed Longitudinal member and Floor panel are tried in regular production tooling which result substantial weight and cost reduction. This report is first of its kind where the concept was tried for the first time in the commercial vehicle industry.