A special version of lightweight design, the use of relief-embossed panels, will be detailed using the rear wall built into a Mercedes-Benz roadster. The conflict involved in 'retaining the performance characteristics of the embossed panel versus the requirements of a car body structure' forms the focal point of this analysis. The emphasis is directed to the forming technology which was developed in order to ensure cost-effective production of the rear wall. The entire process chain beginning with embossing the sheet metal and ending with joining the part will be described. Both, a series production solution for the component mentioned above and further potential improvements will be shown. In order to enable cost-effective exploitation of the advantages of embossed semi-finished products, the characteristics must be precisely coordinated to the relevant body load case. The use of relief-embossed panels in an extended range of parts will only be possible if the following, necessary further developments are implemented: the production of partially-embossed blanks in a continuous process ('path embossing', reduction of process costs, particularly in combination with further roll forming steps) must be achieved, the specific application of locally embossed areas must be possible (no flattening necessary, increased component precision, extended component spectrum), hemming of outer panels on embossed panels should be enabled and the qualification/employment of additional joining processes must be proven.
Forming of relief-embossed panels and actual use in an automotive body
Umformen eines reliefgeprägten Blechteils und die aktive Verwendung bei der Autokarosserie
2005
4 Seiten, 10 Bilder, 2 Quellen
Aufsatz (Konferenz)
Englisch
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