Abstract: To evaluate a suitable modeling method for tailor welded tube hydroforming, three styles of weld-seam model, i.e., comprehensive model, rough model and no weldseam model, are put forward and studied according to laser welding joint material properties. By comparing with experimental results, effects of modeling styles on simulation precision, such as thickness distribution and geometry shape, are analyzed. It indicates that weldseam is a key factor to affect simulation precision. But affected zone is limited to three times of weldseam width. Over thinning deformation character can be simulated successfully only when weldseam model is built. It is worthwhile to note that little deference happens between comprehensive and rough models in simulation precision. The maximal error of simulation results are both less than 6.5%. At last, the suitable weld-seam modeling is given by comparing thickness and shape simulation accuracy, which is useful for further analysis of laser tailor-welded tube hydroforming.

Key words: Error size, Hydroforming, Laser welding, Weld-seam modeling