Rounding during extrusion is a manufacturing process for producing curved profiles, which demonstrates a range of outstanding advantages over the conventional process chain of extrusion, stretching and bending. To improve its industrial usability, a great number of new system components have been developed, which create the necessary process chain with the help of the adapted control software. Methods are used to safeguard manufacturing accuracy and to beat current industrial requirements, so that IHU calibration of the profiles is no longer needed. What is more, tests to produce consistent and variable rounded profiles have been carried out on an industrial production extruder. Profile geometries from the structural design of a track vehicle manufacture as well as from the motor vehicle sector were used. The rounded components are both free of residual stresses and demonstrate uniform strength over the whole length of the component. The additional innovative manufacture of rounded magnesium profiles increased the level of difficulty for the project partners at the start of the project, in the production of profiles, but rounded magnesium profiles have already been produced in trials with no problems. These profiles aroused particular interest from the associated partners and other external companies, because with conventional manufacturing of magnesium profiles, this is only possible at high temperatures, because of the low flexibility level in the hexa-diagonal grid of magnesium. Magnesium extruded profiles are becoming increasingly important, because they permit a reduction in mass, whilst meeting the requirements in terms of strength and bending stiffness. This is particularly useful in creating the lowest possible wall thicknesses. Magnesium space-frames are seen as a vision of the future, but require further work, particularly in terms of materials, forming and jointing. The manufacture of curved profiles from magnesium would represent a very promising application for this process. In order to demonstrate the anticipated improvements in the mechanical properties of curved components, experimental crash tests, such as quasi-static bending and dynamic drop tower test, will be carried out at the Institute for Motor vehicles in Aachen (fka).
Extrusion of curved aluminium profiles for structural parts in vehicles
Gekrümmte Strangpressprofile aus Aluminium für Strukturbauteile in der Fahrzeugtechnik
2003
14 Seiten, 14 Bilder, 5 Quellen
Aufsatz (Konferenz)
Englisch
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