Optimizing tailor rolled blanks: a computational study on mechanical and deformation properties

In recent years, significant attention has been garnered by Tailor Rolled Blanks (TRBs), especially within the automotive industry, attributed to their unique performance characteristics, defined by varying thickness profiles. Nonetheless, the inherent structural complexities of TRBs have led to non-uniform deformation during forming processes, thereby compromising elongation and formability. In this study, an exploration into the deformation of TRBs under uniaxial tensile conditions is elucidated, centering specifically on TRBs transitioning from a thickness of 1–2 mm over a 100 mm span. An assessment of the properties of TRBs following partial annealing is conducted, and mechanisms responsible for thickness variations and the revelation of intrinsic mechanical traits are identified through microstructural examinations. Exploration of the mechanical behavior of TRBs under tension is undertaken, and a methodological approach for optimizing the distribution of mechanical properties is proposed. Validation is achieved through the employment of finite element models, showcasing a performance improvement in the optimized TRBs, with uniform elongation rates surpassing those of non-optimized TRBs by up to 197%. Moreover, an outperformance of uniform-thickness materials by up to 51% is exhibited by the optimized TRBs. These insights are anticipated to bolster the application and efficiency of TRBs across various engineering sectors, aligning coherently with the intelligent design and advanced materials implications within the realm of mechanics and materials in design, as spotlighted by "The International Journal of Mechanics and Materials in Design". This exploration intricately intertwines mechanics, material engineering, and intelligent design, offering a comprehensive view that stands to fortify the symbiotic relationship between advanced materials and the design process.