Formability evaluation of tailor rolled blank (TRB) with the forming limit margin field graph

Tailor rolled blank (TRB) with graded thickness has shown great potential in the automobile field. Using traditional forming limit diagrams (FLDs) to evaluate TRB formability is challenging due to thickness variations. In this paper, a 3D forming limit surface (FLS) considering the influence of thickness was obtained. A numerical model was developed to predict final strains. Moreover, a forming margin was denoted and calculated to generate the forming limit margin field graph for quantitative evaluation of the TRB formability. Results showed that as the punch travel increased, the forming margin value decreased. As the travel changed from 35.2 mm to 37.4 mm, the corresponding forming margin value changed from 0.002 to -0.024. The formability declined, and the specimen eventually cracked on the thinner side. Besides, the deformation and strain paths predicted by simulation agreed well with those measured from formed part, which indicated that the final strains used in formability evaluation were reliable. The method was suitable for quantitative evaluation of the formability and predicting the cracking position in TRB forming.