In order to manufacture components optimised in regard to lightweight construction, the use of innovative forming processes like high‐pressure sheet metal forming (HBU) in combination with the use of tailor rolled blanks (TRB) as innovative semi‐finished materials is a promising solution. To realise a sufficient forming process reliability, at first, investigations on the seal system were carried out. Hereby, a non‐adjustable as well as a new adjustable seal system have been investigated and qualified as sufficient solutions for this process depending on thickness ratio and thickness gradient within the TRB. One typical workpiece geometry which offers a promising lightweight potential and which can be manufactured from TRB with the HBU‐process is the class of body structures. Therefore, an idealised large scale structure has been designed and investigated in theoretical (numerical) and experimental research. The research work has shown that this large scale structure can be manufactured sufficiently by the HBU of TRB.
In order to manufacture components optimised in regard to lightweight construction, the use of innovative forming processes like high‐pressure sheet metal forming (HBU) in combination with the use of tailor rolled blanks (TRB) as innovative semi‐finished material is a promising solution. Fundamental investigations on the HBU of TRB have been carried out in a joint research project at the Institute of Forming Technology and Lightweight Construction (IUL), University of Dortmund, and the Institute of Metal Forming (IBF), RWTH Aachen. The experiments performed with cylindrical parts have provided basic knowledge on the sheet material flow and resulting part properties. To achieve sufficient process reliability, a non‐adjustable as well as an adjustable seal system have been tested and proved to be suitable solutions, depending on thickness ratio and thickness gradient within the TRB. In order to demonstrate the lightweight potential of this process chain, a forming tool for an automotive body structure has been designed and tested. The experiments have shown that this large‐scale structure can well be manufactured in the HBU process from a TRB.
A promising approach to control the material flow within deep drawing and workingmedia based forming processes is the structuring of the tool surfaces in the contact zones between workpiece and die. In order to obtain a sufficient and an optimised material flow respectively – especially for non-symmetric or non-uniform workpiece geometries – a locally adapted distribution of surface structures is a practicable solution. The macroscopic, and also the microscopic surface structures can be manufactured sufficiently by means of a high-speed cutting process. The shape of the tool surface structure has a significant influence on the tribological conditions between workpiece and die. To adjust the surface structure distribution to the required material flow distribution, detailed knowledge about the correlation of the material flow from the tribological conditions between sheet and the forming tool is required. A further innovative approach, particularly for decreasing the friction coefficient, is the use of an innovative hydrostatic pressure system using fluid ducts. Its functional principle is based on the reduction of the contact shear stress at the sheet surface in the contact zone with the forming tool by means of locally applying a hydrostatic fluid pressure. To obtain information about the correlation of the material flow from the tool surface structures and from the parameters of the hydrostatic pressure system respectively, fundamental investigations have been carried out. In order to optimise the material flow, these toolbased approaches can be used as stand-alone solution, or in addition to other systems. If the surface structures and a hydrostatic pressure system are used in combination with the multi-point blank holder, which has already been qualified for the high-pressure sheet metal forming (HBU), a powerful system for the material flow control is available.
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