A long term objective of automobile and truck industry is to partly substitute press formed parts by roll formed components because of their higher efficiency and flexibility. In recent years it was developed a new flexible roll forming technology allowing variable cross sections of profiles by adaptive roll stands. This promising technology is especially suitable for high and ultra high strength steels because of their simple bending operations along a line and the possibility to adjust and calibrate the higher elastic spring back within the production line itself. Thus, a high efficient production technology could be used to make profiles with load optimized contours and design structures with the minimal weight to achieve the targets of the parts. With these load optimized structures it would be possible to reduce the dead loads of cars and trucks by more than 20%. Once a tool set for a part is produced, new dimensions of other parts of the same family could be produced by simple changing of the position of the roll tools. This allows the effective production of small lot sizes and a few prototypes without the need of new tools. A new prototype and experimental unit of the so called 3rd generation with improved capability of the adaptive roll stands and flexible blank holders will be realized at data M till the end of this year. The paper deals with CNC controlled forming stands and finite element analysis to avoid edge wrinkling and warping effects and achieve acceptable tolerances in industrial quality.
Fabrication of Load Optimized Truck Members with Variable Cross Sections by Flexible Roll Forming
Herstellung belastungsoptimierter LKW-Bauteile mit variablen Querschnitten durch flexibles Rollformen
2011
8 Seiten, 10 Bilder, 11 Quellen
Conference paper
English
Bewegungssteuerung , Finite-Elemente-Methode , flexibles System , Gewichtseinsparung , Karosseriekomponente , Lastkraftwagenzubehör , Niederhalter , Pilotanlage , Prototyp , Prozessentwicklung , Prozessoptimierung , Prozesssimulation , Rollformen , Software , ungleichmäßiger Querschnitt , Walzprofilieren
Flexible roll forming process design for variable cross-section profile
Online Contents | 2015
|Flexible roll forming process design for variable cross-section profile
British Library Online Contents | 2015
|Flexible roll forming process design for variable cross-section profile
Springer Verlag | 2015
|Unconventional Truck Chassis Design with Multi-Functional Cross Members
British Library Conference Proceedings | 2019
|Unconventional Truck Chassis Design with Multi-Functional Cross Members
SAE Technical Papers | 2019
|