Vehicle safety devices play a crucial role in protecting occupants and reducing the severity of traffic accidents. Airbags, protection bars, seat belts, the Anti-lock Braking System (ABS), and others perform specific functions to mitigate damage in the event of collisions. Side protection bars, also known as door beams, are important components in vehicles, designed to enhance occupant safety in the event of a side collision. These bars are generally made of high-strength tubular or stamped steel and are installed inside the vehicle doors. Among the design configurations, the focus was on those made with martensitic steel tubes welded to stamped parts known as brackets. These high-strength tubes must be laser cut, a technology widely used in the automotive industry, especially for cutting high-hardness sheets, such as those with high martensite content. However, there are drawbacks associated with this type of cutting, such as splashes of molten material expelled by gas pressure, irregular cutting roughness, and laser residue when the cut is made on part of a tube. This requires careful planning of the cut to avoid compromising the performance of the produced part. Another drawback associated with laser cutting and subsequent welding is the residual stresses present in the material after processing due to the associated temperature gradient. Therefore, in this study, an analysis of this residual was conducted to quantify its value and region, where it was found that they can reach values on the order of 1000 MPa. This is not exactly a problem, as corresponding values have been found in the literature, and the material, being predominantly martensitic (with a maximum stress of 1600 MPa), can accommodate this level of stress.

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Study of Residual Stresses in Laser Cutting of High Strength Welded Tubes for Use in Vehicle Impact

  • Luis Fernando Folle,
  • Tiago Nunes Lima,
  • Matheus Passos Sarmento Santos,
  • Renato Batista da Cruz,
  • Marco Antônio Colosio,
  • Rodrigo Santiago Coelho

摘要

Vehicle safety devices play a crucial role in protecting occupants and reducing the severity of traffic accidents. Airbags, protection bars, seat belts, the Anti-lock Braking System (ABS), and others perform specific functions to mitigate damage in the event of collisions. Side protection bars, also known as door beams, are important components in vehicles, designed to enhance occupant safety in the event of a side collision. These bars are generally made of high-strength tubular or stamped steel and are installed inside the vehicle doors. Among the design configurations, the focus was on those made with martensitic steel tubes welded to stamped parts known as brackets. These high-strength tubes must be laser cut, a technology widely used in the automotive industry, especially for cutting high-hardness sheets, such as those with high martensite content. However, there are drawbacks associated with this type of cutting, such as splashes of molten material expelled by gas pressure, irregular cutting roughness, and laser residue when the cut is made on part of a tube. This requires careful planning of the cut to avoid compromising the performance of the produced part. Another drawback associated with laser cutting and subsequent welding is the residual stresses present in the material after processing due to the associated temperature gradient. Therefore, in this study, an analysis of this residual was conducted to quantify its value and region, where it was found that they can reach values on the order of 1000 MPa. This is not exactly a problem, as corresponding values have been found in the literature, and the material, being predominantly martensitic (with a maximum stress of 1600 MPa), can accommodate this level of stress.