metals
Article
The Optimization of Welding Spots’ Arrangement in A-Pillar
Patchwork Blank Hot Stamping
Wenfeng Li, Zhiqiang Zhang *, Hongjie Jia and Mingwen Ren
Citation: Li, W.; Zhang, Z.; Jia, H.;
Ren, M. The Optimization of Welding
Spots’ Arrangement in A-Pillar
Patchwork Blank Hot Stamping.
Metals 2023, 13, 1409. https://
doi.org/10.3390/met13081409
Academic Editor: Jean-Michel
Bergheau
Received: 26 June 2023
Revised: 30 July 2023
Accepted: 4 August 2023
Published: 6 August 2023
Copyright: © 2023 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Metals 2023, 13, 1409. https://doi.org/10.3390/met13081409
Key Laboratory of Automobile Materials, Ministry of Education, School of Material Science and Engineering,
Jilin University, 5988 Renmin Street, Changchun 130022, China
* Correspondence: zhangzq@jlu.edu.cn
Abstract: With increasingly severe environmental problems, energy saving and environmental
protection have become two important issues to be solved in the automobile industry. Patchwork
blank hot-stamping technology can be used to obtain light-weight and high-strength parts and is thus
increasingly used in the manufacture of autobody parts. Because the main blank and the patched
blank need to be connected through spot welding before forming, the welding spots’ arrangement
has a great influence on the formability of the part. In this study, a thermal–mechanical coupling
finite element analysis model of A-pillar patchwork blanks was established. With the thickness of the
patched blank, the distance between the welding spot and the external contour of the patched blank,
and the number of welding spots as optimization variables, together with the maximum thinning
rate and the maximum welding spot force as objectives, the influence of welding spot arrangement
on forming quality was analyzed, and the welding spots’ arrangement was optimized using a central
composite design (CCD), the response surface method (RSM), and the genetic algorithm (GA). The
results showed that when the initial welding spot was located close to the contour of the patched
blank, the bending moment was greater when the weld spot passed through the die corner, leading
to the rupture of the welding spot or its surrounding base material due to the greater thinning
rate. When the patched blank was thicker than the main blank, the main blank cracked during the
forming process due to a greater increase in the thinning rate. The optimal solution of the weld
spot arrangement on the A-pillar patchwork blanks was a 1.2 mm thick main blank, 0.8 mm thick
patched blank, a distance of 29 mm between the weld spot and the contour line of the patched blank,
and 16 weld spots. Hot-stamping experiments were conducted using the optimized weld spots’
arrangement, and high-quality parts were obtained.
Keywords: lightweight; patchwork blanks; hot stamping; response surface method; genetic algorithm;
thinning rate
1. Introduction
In order to meet strict environmental requirements, achieve fuel economy, and reduce
vehicle exhaust pollution, the application of lightweight materials in automobile bodies is
becoming increasingly widespread. Among these materials, 22MnB5 boron steel, with the
advantages of a high strength, low cost, and good cost performance, is gradually becoming
favored [1–4]. Hot stamping has gradually replaced cold stamping, which can reduce
effects such as springback and wrinkling during the stamping process and is also beneficial
for extending the service life of the die. The hot-stamping forming process involves heating
boron steel until it is fully austenitized and then quickly closing the dies for forming and
quenching to obtain high-strength parts with tensile strengths of over 1500 MPa [5–7]. In
recent years, in order to improve the safety of collision, it has become necessary to design
customized parts with partition strength and toughness in the case of some boron steel
structural parts. Hot-stamping patchwork blank technology is a new method used to
produce customized parts, which has the advantages of a good applicability and low cost
https://www.mdpi.com/journal/metals
Metals 2023, 13, 1409 2 of 13

and is more and more widely used in the manufacture of customized parts. At present, the
main welding methods for patchwork blanks’ hot stamping are resistance spot welding,
laser welding, and arc welding [8–10]. Considering the cost and efficiency of automobile
production, resistance spot welding is a common connection method. Patchwork blank
hot stamping is first used to connect the main blank and patched blank together via spot
welding, and then the connected the main blank and patched blank are heated and hot-
stamped together. Then, the patchwork parts with a given partition strength and toughness
are obtained. The patchwork blank hot-stamping forming technology can be used to obtain
different thickness and shapes of the main blank and patchwork blank. Compared with
a continuously variable cross-section blank, the patchwork blanks can be more flexible,
allowing one to adjust the mechanical properties of parts. Since the main blank and the
patchwork blank are connected before hot-stamping forming, the number of required dies
can be reduced. This method has been widely used in automobile A-pillar, B-pillar, and
front reinforcement beams, among others [11–13]. Its advantages are a good collision safety,
high bending load, local reinforcement, and good lightweight effects. Klaus et al. [14] used
numerical simulation methods for the hydroforming patchwork blanks and carried out
an experimental verification, providing a suitable model for the numerical simulation
of patchwork blanks’ forming process. Gao et al. [15] studied the influences of spot
welding parameters on the connection performance of hot-stamped patchwork blanks and
successfully produced a B-pillar reinforcement. Wang et al. [16] conducted an effective
experimental study and finite element analysis of patchwork blanks, verified the accuracy
of the patchwork blank hot-forming finite element model, and outlined the principle of
the welding spots’ arrangement. However, the material near the welding spot can easily
become thin and crack during the hot-stamping process, which affects not only the forming
quality but also the stability of the production process [17–19]. At present, there are still
two problems that need to be solved for the hot stamping of patchwork blanks. First, the
quality of the spot-welding connection should be controlled before hot stamping to ensure
that the welding spot is not deformed or cracked after the hot stamping. Second, due to the
difference in thickness between the main blank and the patched blank area and the existence
of welding spots, the forming ability will be reduced to a certain extent compared with the
uniform thickness sheet. If the welding spots are not properly arranged, an uneven material
flow will easily occur during the hot-stamping process, thus increasing the possibility of
wrinkling and cracking in the hot-stamping process of patchwork blanks [20,21].
In this study, a finite element method was used to simulate and analyze the hot
stamping forming process of A-pillar patchwork blanks. The influences of the number of
welding spots, the thickness of the patched blank, and the distance between the welding
spot and the external contour of the patched blank on the thinning rate and welding spot
force were studied using a central composite design (CCD), the response surface method
(RSM), and the genetic algorithm (GA) multi-objective optimization method to obtain the
optimal welding spot arrangement. Based on this, hot-stamping experiments of the A-pillar
patchwork blanks were conducted to verify the optimization results.

2. Establishment of Finite Element Model for A-Pillar Patchwork Blanks

The material of A-pillar patchwork blanks is 22MnB5 steel. Its chemical composition
is shown in Table 1, and its physical and thermal parameters at different temperatures are
shown in Table 2 [22–25].

Table 1. Chemical composition of 22MnB5 (w%).

C Si Mn P B Cr Ti Fe
≤0.25 0.23 1.2 ≤0.02 0.003 ≤0.20 ≤0.30 Bal.
Metals 2023, 13, x FOR PEER REVIEW 3 of 13
Metals 2023, 13, 1409 3 of 13
Metals 2023, 13, x FOR PEER REVIEW 3 of 13

Table 2. 22MnB5 physical and thermal parameters.

Table 2. 22MnB5 physical and thermal parameters.
Table 2. 22MnB5 physical
Temperature and thermal parameters.
(°C) 20 500 600 700 800 900
Temperature ◦ C)
(E 20 500 600 700 800 126900
Elasticity modulus
Temperature (°C)(MPa) 212 20 158 500 150 600 142 700 134 800 900
Poisson’s
Elasticity ratio
modulus E ν(MPa)
Elasticity modulus E (MPa) 0.284
212 212 0.303
158 1580.301
150 1500.317
142 142 0.325
134 0.334
134 126126
Poisson’s ratio
Thermal conductivity ν(W/m °C)
Kratio 0.284
32.00.2840.303
22.30.3030.301 0.317
23.60.30124.5 0.325 26.7
25.6 0.334
Poisson’s
Thermal conductivity K (W/m C) ν ◦ 32.0 22.3 23.6 24.50.317 0.325
25.6 0.334
Specific heat capacity
Thermal Cp (J/kg ◦°C) 412 573 581 586 590 59626.7
Specific heatconductivity K (W/m
capacity Cp (J/kg C) °C) 412 32.0573 22.3581 23.6 586 24.5 59025.6 596 26.7
TheSpecific
thicknesses
heat of the main
capacity Cp blank and the patched
(J/kg °C) 412 blank are
573 5811.2 mm 586and 1.5 590mm,596
respectively, and the overall dimensions of the part are 692 mm × 380 mm × 115 mm, as
The thicknesses
thicknesses of of the
the main
main blank
blank and
and the patched
patched blank
blank areare 1.2
1.2 mm
mm andand 1.5
1.5 mm,
shown inThe Figure 1. Uniaxial tensile tests of the the
22MnB5 at different temperatures andmm,
respectively, andand the
the overall
overall dimensions
dimensions of of the part
part are 692
692 mmmmto××obtain
380
380mm × 115115mm, as
respectively,
strain rates were carried out using a Gleeble 1500 thetesting are
machine mmthe ×stress–mm,
shown
as curves in
shown at Figure 1.
in different Uniaxial
Figure 1. temperaturestensile
Uniaxial tensile tests of the
tests of the 22MnB5 at different
22MnB5 atcurves
different temperatures
temperatures and
strain [26,27].The stress–strain of the material atand
strain rates were
straintemperatures carried
rates were carried out using
out using a Gleeble
a Gleeble 1500
1500the testing
testing machine
machine to obtain
to obtain thethe the stress–
stress–strain
different are shown in Figure 2. With increase in temperature, rheo-
strain curves
curves at at different
different temperatures
temperatures [26,27].The
[26,27].The stress–strain
stress–strain curves ofcurves
the of the at
material material
differentat
logical stress of the material decreases.
different temperatures are shown in Figure 2. With the increase in temperature,
temperatures are shown in Figure 2. With the increase in temperature, the rheological stress the rheo-
logical
of stress ofdecreases.
the material the material decreases.

Figure 1. A-pillar patchwork blanks. (a) Part. (b) Blanks. Note:main blank red; patched blank purple.
Figure 1. A-pillar
Figure1. A-pillarpatchwork
patchworkblanks.
blanks.(a)
(a)Part.
Part.(b)
(b)Blanks.
Blanks.Note: main blank
Note:main blankred; patched
red; blank
patched purple.
blank purple.

Figure
Figure 2. The
2. The stress−strain
stress−strain curves
curves of 22MnB5
of 22MnB5 at different
at different temperatures.
temperatures.

The
Figure 2. dies’ arrangement
The stress−strain for the
curves hot stamping
of 22MnB5 of the
at different A-pillar patchwork blanks is shown
temperatures.
The dies’ arrangement for the hot stamping of the A-pillar patchwork blanks is
in Figure 3. The friction coefficient was set to 0.45, and the heating temperature of the blank
shown in Figure 3. The friction coefficient was set to 0.45, and the heating temperature of
The◦ Cdies’
was 930 so asarrangement for the hot
to render it completely stamping [28,29].
austenitized of the A-pillar patchwork
The transfer blanks
time was 8 s, theis
shown in Figure 3. The friction coefficient was set to 0.45, and the heating temperature of
Metals 2023, 13, x FOR PEER REVIEW 4 of 13

Metals 2023, 13, x FOR PEER REVIEW 4 of 13

Metals 2023, 13, 1409 4 of 13

the blank was 930 °C so as to render it completely austenitized [28,29]. The transfer time
was 8 s, thewas
the blank tool930
temperature
°C so as towas 70 °C,
render and the stamping
it completely stroke[28,29].
austenitized was 200Themm. The waiting
transfer time
time of the
wastemperature blank in the die
8 s, the tool temperature before
wasthe the punch
70stamping touched
°C, and the the
stamping blank
stroke was
was set to 2 s. The quench-
tool
ing time was 7 s,was
and 70 ◦ C, and
the holding force stroke
was touched
5000 kNwas 200
during mm. The200
quenching.
mm. The
waiting timewaiting
of the
time of the blank in the die before the punch the blank was set
blank in the die before the punch touched the blank was set to 2 s. The quenching timeto 2 s. The quench-
was
7ing timethe
s, and was 7 s, and
holding the was
force holding
5000force was 5000
kN during kN during quenching.
quenching.

Figure 3. The dies’ arrangement for the hot stamping of the A-pillar patchwork blanks.
Figure3.3.The
Figure Thedies’
dies’arrangement
arrangementfor
forthe
thehot
hotstamping
stampingofofthe
theA-pillar
A-pillarpatchwork
patchworkblanks.
blanks.
Figure 4 shows the simulation results without the optimization of the welding spots’
Figure
Figure44shows
shows the
thesimulation
simulation results
resultsitwithout
without the
the optimization
optimization of
of the
the welding spots’
arrangement. In hot-stamping analysis, is generally required that the welding
maximum spots’
thin-
arrangement. In hot-stamping analysis, it is generally required that the
arrangement. In hot-stamping analysis, it is generally required that the maximum thin-maximum thinning
ning rate of the material is no more than 17%; otherwise, the material is considered to be
rate
ningofrate
theofmaterial is noismore
the material thanthan
no more 17%; otherwise,
17%; otherwise, thethe
material
materialisisconsidered
consideredtotobe be
cracked. ItIt can
cracked. canbebeseen
seenthat
thatthe
thethinning
thinningrate rateofofthe
the main blank around the welding spots
cracked. It can be seen that the thinning rate of the main blank around thewelding
main blank around the weldingspots
spots
on the
on the sidewallisis30.7%,
30.7%, farexceeding
exceeding therequirement
requirement of 17%. To reduce the excessive
on thesidewall
sidewall is 30.7%,far far exceedingthe the requirementof of17%.
17%. To
Toreduce
reducethe theexcessive
excessive
rate
rate of thinning around the welding spots, the central composite design, response surface
rateof
ofthinning
thinningaround
aroundthe thewelding
weldingspots,
spots,the thecentral
centralcomposite
compositedesign,
design,response
responsesurface
surface
methods,
methods, and genetic algorithm multi-objective optimization method were used to opti-
methods,and andgenetic
geneticalgorithm
algorithm multi-objective
multi-objective optimization
optimization method werewere
method usedused
to optimize
to opti-
mize
the the formability
formability of the
of the A-pillar A-pillar
patchwork patchwork
blanks, and blanks, and the
the optimization optimization shown inis is
process
process is process
mize the formability of the A-pillar patchwork blanks, and the optimization
shown5.in Figure 5.
Figure
shown in Figure 5.

Figure4.4.
Figure
Figure 4.Simulation
Simulationresults
Simulation results before
resultsbefore the
beforethe optimization
theoptimization ofofof
optimization the
thethewelding
welding
welding spots’
spots’
spots’ arrangement.
arrangement.
arrangement.
Metals 2023,
Metals 13,13,
2023, x FOR
1409PEER REVIEW 5 of5 13
of 13

Figure 5. Chart of the A-pillar patchwork blank welding spots’ optimization process.
Figure 5. Chart of the A-pillar patchwork blank welding spots’ optimization process.
3. Response Surface Method Hot Stamping of A-Pillar Patchwork Blanks
3. Response Surface Method Hot Stamping of A-Pillar Patchwork Blanks
The central composite design is the most commonly used response surface design for
The centralcomposed
experiments, compositeof design is the
a factor mostorcommonly
design partial factor used response
design withsurface
a centraldesign
pointfor
and
experiments, composed of a factor design or partial factor design with
enhanced by a group of axis points (or star points). By adding center points and axis points a central point and
enhanced by a grouprun
to the previously of axis
factorpoints (or star
design, thispoints).
methodByhas adding center points
the advantages ofand axis points
covering a wide
to design
the previously run factor design, this method has the advantages
space and obtaining accurate high-order information. During the hot-stamping of covering a wide
design space
process andpatchwork
of the obtaining accurate
blanks, the high-order
area betweeninformation.
the weldingDuring theand
spot hot-stamping
the external
process
contourof the patchwork
of the patchedblanks,blank isthe area to
prone between the welding
an excessive spotrate,
thinning and which
the external
leads con-
to the
tour of the
crack patched
of the blank isaround
base material prone to theanweld
excessive
spots. thinning
At the same rate,time,
which theleads
number to the crack
of welding
of spots
the base material
is also around thefactor
an important weld spots. At the
affecting thesame
formingtime,performance
the number of ofwelding spots
the patchwork
is blanks.
also an Exploring
importantthe factor affecting the forming performance of the
number of welding spots required for the motherboard with differentpatchwork blanks.
Exploring
thicknessthe number of welding
combinations is also ofspots
greatrequired
significancefor the
for motherboard
optimizing thewith different
structure thick-
of the patch
ness combinations
plate and improving is alsotheofforming
great significance
performance. for In
optimizing
addition, the the structure
stress on of the patch
welding spots
plate andhot
during improving
stamping theis forming performance.
also an important indexInwithaddition,
whichthe stress onthe
to evaluate welding spots of
formability
patchwork
during blanks, is
hot stamping which
also anhasimportant
an important indexinfluence
with which on to
theevaluate
performance of patchwork
the formability of
blanks. Hence,
patchwork blanks,the thickness
which has an ofimportant
the patched blank Xon
influence 1 , the
the distance
performance between of the welding
patchwork
spots Hence,
blanks. and thethecontour of theofpatched
thickness the patchedblankblank
X2 , and X1,the
thenumber
distanceofbetween
welding the spots X3 were
welding
selected
spots and theas optimization
contour of thevariables,
patched blankand theX2, maximum
and the number thinning rate andspots
of welding the maximum
X3 were
tensile as
selected shear force on the
optimization welding
variables, andspots during thethinning
the maximum forming rate process
and were studied as
the maximum
objective
tensile shearfunctions.
force on the Thewelding
thickness of the
spots mainthe
during blank was 1.2
forming mm, and
process werethe patched
studied as blank
ob-
thickness
jective was inThe
functions. the thickness
range of 0.8–1.6
of the mm.main Ifblank
the distance
was 1.2between
mm, andthe thewelding
patched spots and
blank
the contour of the patched blank is too small, the main blank
thickness was in the range of 0.8–1.6 mm. If the distance between the welding spots and is prone to cracking. The
distance between the welding spots and the contour line of the
the contour of the patched blank is too small, the main blank is prone to cracking. The patched blank was selected
to be inbetween
distance the rangetheofwelding
12–40 mm. spotsBecause
and the the welding
contour line spots
of the on the bottom
patched blank wasof the forming
selected
to be in the range of 12–40 mm. Because the welding spots on the bottom of the forming
Metals 2023, 13, 1409 6 of 13

part have little influence on the forming quality, only the welding spots on the side wall
after forming were optimized. The number of sidewall welding spots ranged from 4 to
20. The values of the design variables X1 , X2 , and X3 are shown in Table 3. Based on the
central composite design principle, a total of 20 groups of tests were conducted, and the
experimental scheme and results are shown in Table 4.

Table 3. Design factors and levels for the optimization of patchwork blank parameters.

Levels
Design Factors
−1 0 1
X1 (mm) 0.8 1.2 1.6
X2 (mm) 12 26 40
X3 4 12 20

Table 4. Experimental scheme and simulation results.

Design Factors Thinning Rate Welding Spot Force

Experiment Number
X1 (mm) X2 (mm) X3 Y1 (%) Y2 (N)
1 0.8 12 4 24.7 2553
2 1.6 12 4 31.2 2785
3 0.8 40 4 20.6 2453
4 1.6 40 4 22.8 2501
5 0.8 12 20 23.1 2245
6 1.6 12 20 30.4 2584
7 0.8 40 20 14.5 2177
8 1.6 40 20 15.4 2352
9 0.8 26 12 14.6 2232
10 1.6 26 12 17.7 2375
11 1.2 12 12 29.9 2476
12 1.2 40 12 15.0 2327
13 1.2 26 4 23.9 2552
14 1.2 26 20 19.3 2373
15 1.2 26 12 17.3 2253
16 1.2 26 12 17.3 2253
17 1.2 26 12 17.3 2253
18 1.2 26 12 17.3 2253
19 1.2 26 12 17.3 2253
20 1.2 26 12 17.3 2253

The response surface models for the maximum thinning rate Y1 and maximum weld
spot force Y2 based on the results in Table 4 are shown in Equations (1) and (2):

Y1 = 14.97148 + 43.76238x1 − 1.02883x2 − 1.146551x3 − 0.238839x1 x2 − 0.019531x1 x3 − 0.012388x2 x3

(1)
−13.46591x21 + 0.021150x22 + 0.051491x23

Y2 = 2582.89549 + 688.57224x1 − 17.35005x2 − 77.89261x3 − 7.76786x1 x2 + 9.14062x1 x3 + 0.09375x2 x3

(2)
−150.85227x21 + 0.0376855x22 + 2.10724x23
The variance analysis of the maximum thinning rate Y1 and the maximum weld spot
force Y2 are shown in Tables 5 and 6. The magnitude of the F-value reflects the degree
of the interactive effect, while the p-value reflects the degree of significance (usually, for
models, p < 0.01 indicates highly significant, and p < 0.005 indicates significant). A larger
F-value and smaller p-value can reflect the significance of the correlation coefficient. The
model p-values of the response surfaces for both the maximum thinning rate and the weld
spot force are less than 0.005, indicating that the model is significant. This shows that the
fitting accuracy is good, and the response surface approximation model can be used for
subsequent optimization design. It can be seen from Table 5 that the F-values of the linear
terms X1 , X2 , X3 and the quadratic terms X12 , X22 , X32 are less than 0.005, indicating that the
effect on the thinning rate of the patch board is extremely significant, and the other factors
Metals 2023, 13, 1409 7 of 13

are not significant. From Table 6, it can be seen that the F-value of the first terms X1 , X2 , and
X3 and the second term X32 is <0.005, indicating that the influence on the solder joint force of
the patch plate is extremely significant, and the other factors are not significant. According
to the F-value, it can be concluded that the factors affecting the maximum thinning rate,
from strong to weak, are the distance between the welding spot and the contour of the
patched blank X2 , the number of weld spots X3 , and the thickness of the patched blank X1 ,
while the factors affecting the weld spot force, from strong to weak, are the number of weld
spots X3 , the thickness of the patched blank X1 , and the distance between the welding spot
and the contour of the patched blank X2 .
Table 5. Variance analysis of maximum thinning rate.

Quadratic Degree of Average

Source F-Value p-Value
Sum Freedom Variance
Models 521.08 9 57.9 31.55 <0.0001
X1 40 1 40 21.8 0.0009
X2 260.1 1 260.1 141.74 <0.0001
X3 42.02 1 42.02 22.9 0.0007
X1 X2 14.31 1 14.31 7.8 0.019
X1 X3 0.0313 1 0.0313 0.017 0.8988
X2 X3 15.4 1 15.4 8.39 0.0159
X12 12.77 1 12.77 6.96 0.0248
X22 47.26 1 47.26 25.75 0.0005
X32 29.87 1 29.87 16.28 0.0024

Table 6. Variance analysis of welding spot force.

Quadratic Degree of Average

Source F-Value p-Value
Sum Freedom Variance
Models 454,600 9 50,511.31 24 <0.0001
X1 87,796.9 1 87,796.9 41.72 <0.0001
X2 69,388.9 1 69,388.9 32.97 0.0002
X3 123,900 1 123,900 58.86 <0.0001
X1 X2 15,138 1 15,138 7.19 0.023
X1 X3 6844.5 1 6844.5 3.25 0.1015
X2 X3 882 1 882 0.4191 0.532
X12 1602.05 1 1602.05 0.7612 0.4034
X22 15,003.55 1 15,003.55 7.13 0.0235
X32 50,017.55 1 50,017.55 23.76 0.0006

To ensure the validity of the response surface model, the fitting accuracy was verified
using the sample correlation coefficient R2 and the revised correlation coefficient Radj 2 .
When the values of R2 and Radj 2 are close to 1, this indicates that the smaller the relative
error is, the higher the model fitting accuracy is. The results of the accuracy analysis
of the maximum thinning rate and weld spot force response surface models are shown
in Table 7, with correlation coefficients R2 of 0.9660 and 0.9354 and revised correlation
coefficients Radj 2 of 0.9558 and 0.9159, respectively, which indicate that the constructed
second-order response surface models have a good fitting accuracy and can be used for
subsequent optimization.

Table 7. Accuracy analysis of maximum thinning rate and welding spot force response surface model.

Model Correlation Coefficient R2 Revised Correlation Coefficient Radj 2

Y1 0.9660 0.9354
Y2 0.9558 0.9159
 Table 7. Accuracy analysis of maximum thinning rate and welding spot force response surface
model.

Model Correlation Coefficient R2 Revised Correlation Coefficient Radj2

Y1 0.9660 0.9354
Metals 2023, 13, 1409 8 of 13
Y2 0.9558 0.9159
Although analysis of variance can be used to determine whether the constructed re-
sponse surface model has a high fitting accuracy, it cannot be used to evaluate the inter-
Although
action between analysis
design of varianceand
variables canthe be impact
used toon determine whether
the response theTherefore,
results. constructed the
response surface model has a high fitting accuracy, it cannot be used
rule of influence between design variables and their corresponding variables is generally to evaluate the
interaction
explored by between design
creating variables and theresponse
a three-dimensional impact on the response
surface results. two
map between Therefore, the
parameters
rule of influence between design variables and their corresponding
and a response variable and analyzing the corresponding contour line map. The degree variables is generally
explored by creating
of influence between a three-dimensional
the design factors and response surface
response map between
variables is judgedtwo parameters
according to the
and a response variable and analyzing the corresponding contour line
slope angle and curvature change in the response surface and the color gradient distribu- map. The degree of
influence between
tion of the contourtheline
design
map. factors and response variables is judged according to the slope
angle and curvature change in the response surface and the color gradient distribution of
Figure 6 shows the effects of the thickness of the patched blank X1, the distance be-
the contour line map.
tween the welding spot and the contour of the patched blank X2, and the number of weld
Figure 6 shows the effects of the thickness of the patched blank X1 , the distance
spots X3 on the maximum thinning rate Y1. As the thickness of the patched blank in-
between the welding spot and the contour of the patched blank X2 , and the number of weld
creased, the maximum thinning rate showed a gradually increasing trend. When the
spots X3 on the maximum thinning rate Y1 . As the thickness of the patched blank increased,
thickness of the patched blank was greater than that of the main blank, the rigidity of the
the maximum thinning rate showed a gradually increasing trend. When the thickness of
main blank was less than that of the patched blank, which increased the deformation of
the patched blank was greater than that of the main blank, the rigidity of the main blank
the main blank and the thinning rate. With increasing distance between the welding spot
was less than that of the patched blank, which increased the deformation of the main blank
and the contour of the patched blank, the thinning rate [30] gradually decreased. The rea-
and the thinning rate. With increasing distance between the welding spot and the contour
son for this effect is that increasing the distance between the welding spot and the contour
of the patched blank, the thinning rate [30] gradually decreased. The reason for this effect is
of the patched blank reduces the impact of the bending moment on the welding spot dur-
that increasing the distance between the welding spot and the contour of the patched blank
ing thethe
reduces forming
impactprocess, thus reducing
of the bending moment theonthinning rate.spot
the welding The during
effect ofthe
theforming
numberprocess,
of weld
spots on the maximum thinning rate shows a trend of first decreasing
thus reducing the thinning rate. The effect of the number of weld spots on the maximum and then increasing.
In the case
thinning rateof a small
shows number
a trend of welding
of first decreasing spots,
andincreasing the number
then increasing. In theof welding
case spots
of a small
could better
number constrain
of welding spots,theincreasing
patched blank and reduce
the number the thinning
of welding spots rate.
couldHowever, with the
better constrain
continuous increase in the number of welding spots, the stiffness
the patched blank and reduce the thinning rate. However, with the continuous increase of the patched blank
in
increased, the deformation of the main blank increased during the
the number of welding spots, the stiffness of the patched blank increased, the deformationforming process, and
ofthe
thethinning
main blank rateincreased
increased.during the forming process, and the thinning rate increased.

Figure
Figure 6. 6. Response
Response surface
surface and and contour
contour lineline
mapmap of three
of the the three factors
factors showing
showing effectseffects
on theon the maxi-
maximum
mum thinning rate: (a) X1 and X2, (b) X1 and X3, (c) X2 and X3.
thinning rate: (a) X1 and X2 , (b) X1 and X3 , (c) X2 and X3 .

Figure 7 shows the effects of the three factors on the maximum welding spot force
Y2 . With the increasing thickness of the patched blank, the maximum welding spot force
showed a gradually increasing trend. As the thickness of the patched blank increased, the
required forming force increased, and thus, the welding spot force became larger. With
increasing distance between the welding spot and the contour of the patched blank, the
maximum welding spot force gradually decreased. As the distance from the welding spot
to the contour of the patched blank decreased, the bending moment of the welding spot
 With the increasing thickness of the patched blank, the maximum welding spot force
showed a gradually increasing trend. As the thickness of the patched blank increased, the
required forming force increased, and thus, the welding spot force became larger. With
increasing distance between the welding spot and the contour of the patched blank, the
Metals 2023, 13, 1409 maximum welding spot force gradually decreased. As the distance from the welding 9spot of 13
to the contour of the patched blank decreased, the bending moment of the welding spot
decreased during the forming process, and the welding spot force decreased. As the num-
ber of welding
decreased spots
during the increased, the maximum
forming process, weldingspot
and the welding spot force
force showed As
decreased. a downward
the number
trend.
of welding spots increased, the maximum welding spot force showed a downward trend.

Figure
Figure7.7.Response
Responsesurface
surfaceandandcontour
contourline
linemap
mapofofthe
thethree
threefactors
factorsshowing
showingeffects
effectson
onthe
thewelding
welding
spots
spotsforce:
force:(a)
(a)XX1 1and
andXX
2, (b)
2 , X
(b) 1Xand
1 X
and ,
3X (c)
3 , X
(c) and
2X
2 X
and3.X .
3

4.4.Multi-Objective
Multi-ObjectiveOptimization
OptimizationBased
Basedononthe
theNSGA-II
NSGA-IIAlgorithm
Algorithm
According to the response surface analysis, a mathematical model of
According to the response surface analysis, a mathematical model of parameter
parameter opti-
op-
mization was
timization wasestablished,
established,as
asshown
shownininEquation
Equation(3):
(3):
 
0.8 ≤ X ≤ 1.6
min Y (X , X , X ) 0.8 X 1 1.6

Z =Z F=(XF) X= = min Y1 X1 , X 2 , X 3 12 12 ≤XX2 ≤4040 (3)
(3)
minminYY2 (XX1 ,, X
X 2 ,, X
X3 ) 
44 ≤XX3 ≤2020
The NSGA-II genetic optimization algorithm was used to solve the problem. The
The NSGA-II
optimization genetic
process optimization
is shown in Figurealgorithm
8. The crossoverwas used to solve the
probability wasproblem. The op-
0.9, the crossover
timization
distributionprocess
indexiswasshown in Figure
20, the variance8. The crossoverindex
distribution probability
was 20,was the 0.9, thepopulation
initial crossover
number wasindex
distribution 12, thewas
number
20, theof population iterations was
variance distribution index20,was
and 20,
the the
finalinitial
stopping iteration
population
was 240.was
number To 12,
meetthethe real needs
number for the production
of population iterations of was parts, under
20, and thethe condition
final stoppingthat the
itera-
maximum thinning rate is less than 17%, the maximum welding
tion was 240. To meet the real needs for the production of parts, under the condition that spot force is as low as
possible,
the maximumthe optimal
thinning solution
rate is set
lessisthan
the patched
17%, theblank thickness
maximum of 0.8003
welding spotmm, theisdistance
force as low
between
as thethe
possible, welding
optimal spot and the
solution setedge of patched
is the the patched blank
blank is 29.483
thickness of mm,
0.8003andmm, thethe
number
dis-
of welding
tance between spots
the is 16.002.spot
welding Considering
and the edge the of realthe situation,
patched ablank patched blankmm,
is 29.483 thickness
and theof
0.8 mm,of
number a distance
welding between the welding
spots is 16.002. spot and
Considering the the edge
real of the patched
situation, a patched blank
blankof 29 mm,
thick-
and a number of welding spots of 16 were selected as the optimal
ness of 0.8 mm, a distance between the welding spot and the edge of the patched blank of solution.
29 mm, The
andsimulation
a numberresult obtained
of welding spotsunder
of 16 the
were optimal
selected solution conditions
as the optimal is shown in
solution.
Figure 9. Compared with the maximum thinning rate of 30.7% (Figure 4) before optimiza-
tion, the maximum thinning rate was significantly reduced to 14.9% after the optimization
of the welding spots’ arrangement, which meets the hot-stamping production specifications.
Figure 10 shows the evolution of the maximum welding spot force after optimization.
With the increase in the punch stroke, the welding spot force increased, and the welding
spot force decreased rapidly after reaching the maximum of 2249.56 N.
To further verify the influence of the optimized process parameters on the real hot-
stamping quality, an A-pillar patchwork blank part was produced. The formed part is
shown in Figure 11. With the plastic deformation of patchwork blanks, the position of the
weld spots will change. When the weld spots were in the flange position, as the punch
moved downwards, the weld spots moved to the die fillet area, and the force gradually
increased. Near the corner of the die, the weld spot force was the greatest. When the weld
spots entered the side wall area of the part, the resistance was reduced, so that the weld
 Metals 2023, 13, x FOR PEER REVIEW 10 of 13

Metals 2023, 13, 1409 10 of 13

Metals 2023, 13, x FOR PEER REVIEW 10 of 13

spot force was reduced. There were no crack or wrinkling defects in the formed part, and
the welding spots were intact and met the quality requirements.

Figure 8. Chart of the NSGA-II genetic algorithm optimization process.

The simulation result obtained under the optimal solution conditions is shown in
Figure 9. Compared with the maximum thinning rate of 30.7% (Figure 4) before optimi-
zation, the maximum thinning rate was significantly reduced to 14.9% after the optimiza-
tion of the welding spots’ arrangement, which meets the hot-stamping production speci-
fications.
Figure8.8.Chart
Figure Chartofofthe
theNSGA-II
NSGA-II genetic
genetic algorithm
algorithm optimization
optimization process.
process.

The simulation result obtained under the optimal solution conditions is shown in
Figure 9. Compared with the maximum thinning rate of 30.7% (Figure 4) before optimi-
zation, the maximum thinning rate was significantly reduced to 14.9% after the optimiza-
tion of the welding spots’ arrangement, which meets the hot-stamping production speci-
fications.

Figure 9.
Figure 9. Simulation
Simulation results
results after
after optimization
optimization of
of the
the welding
welding spots’
spots’ arrangement.
arrangement.
 Figure 10 shows the evolution of the maximum welding spot force after optimization.
With the increase in the punch stroke, the welding spot force increased, and the welding
Metals 2023, 13, 1409
spot force decreased rapidly after reaching the maximum of 2249.56 N. 11 of 13

Figure 10. Evolution of maximum welding spot force after optimization of the welding spots’ ar-
rangement.

To further verify the influence of the optimized process parameters on the real hot-
stamping quality, an A-pillar patchwork blank part was produced. The formed part is
shown in Figure 11. With the plastic deformation of patchwork blanks, the position of the
weld spots will change. When the weld spots were in the flange position, as the punch
moved downwards, the weld spots moved to the die fillet area, and the force gradually
increased. Near the corner of the die, the weld spot force was the greatest. When the weld
spots entered the side wall area of the part, the resistance was reduced, so that the weld
spot force was reduced. There were no crack or wrinkling defects in the formed part, and
the welding
Figure spotsofwere
10. Evolution intact
maximum and met
welding spotthe quality
force requirements.
after optimization of the welding spots’ arrangement.
Figure 10. Evolution of maximum welding spot force after optimization of the welding spots’ ar-
rangement.

To further verify the influence of the optimized process parameters on the real hot-
stamping quality, an A-pillar patchwork blank part was produced. The formed part is
shown in Figure 11. With the plastic deformation of patchwork blanks, the position of the
weld spots will change. When the weld spots were in the flange position, as the punch
moved downwards, the weld spots moved to the die fillet area, and the force gradually
increased. Near the corner of the die, the weld spot force was the greatest. When the weld
spots entered the side wall area of the part, the resistance was reduced, so that the weld
spot force was reduced. There were no crack or wrinkling defects in the formed part, and
the welding spots were intact and met the quality requirements.

Figure11.
Figure 11.A-pillar
A-pillarpatchwork
patchworkblank
blankpart
partafter
aftermulti-objective
multi-objectiveoptimization.
optimization.

5.5.Conclusions
Conclusions
By
Byoptimizing
optimizingthe
thethickness ofof
thickness the patchwork
the patchwork blanks, thethe
blanks, distance between
distance thethe
between welding
weld-
spot
ing and
spotthe
andcontour of theof
the contour patched blank,blank,
the patched and the number
and of welding
the number spots, the
of welding influence
spots, the in-
law of the
fluence parameters
law on the forming
of the parameters quality was
on the forming obtained.
quality The optimal
was obtained. set of Pareto
The optimal set of
solutions were acquired using the multi-objective optimization NSGA-II algorithm. The
optimal solution of the weld spot arrangement on the A-pillar patchwork blanks was a
1.2 mm thick main blank, 0.8 mm thick patched blank, a distance of 29 mm between the
weld spot and the contour line of the patched blank, and 16 weld spots. Experiments of
the hot-stamping process of A-pillar patchwork blanks with the optimal welding spot
arrangement were carried out. The obtained A-pillar patchwork blanks parts were free
Figure 11. A-pillar patchwork blank part after multi-objective optimization.
of wrinkles and crack defects, which fully proved that the optimization method could
significantly improve the hot-forming ability of patchwork blank hot stamping.
5. Conclusions
By optimizing
Author the thickness
Contributions: of the
W.L. helped patchwork
to perform blanks,with
the analysis the constructive
distance between the weld-
discussions and wrote
ing the
spot and the contour of the patched blank, and the number of welding spots,
manuscript; Z.Z. contributed to the conception of the study; H.J. performed the data the in-
analyses;
fluence law of the parameters on the forming quality was obtained. The optimal
M.R. performed the experiments. All authors have read and agreed to the published version set of of
the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Metals 2023, 13, 1409 12 of 13

Data Availability Statement: Not applicable.

Acknowledgments: We would like to thank Yonggang Li of LingYun GNS Technology Co., Ltd.
for his support and help in the finite element simulation. We would like to thank the anonymous
reviewers for their helpful remarks.
Conflicts of Interest: The authors declare no conflict of interest.

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