High‐Pressure Sheet Metal Forming of Large Scale Structures from Sheets with Optimised Thickness Distribution

Abstract

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.

Properties of Large-Scale Structure Workpieces in High-Pressure Sheet Metal Forming of Tailor Rolled Blanks

“…The HFAsupply plate is integrated inside the press in front of the locking cylinder. The forming of a large-scale structure requires specific attention to the mechanical properties and the operating behaviour of the seal [25]. Simulation and optimisation.…”

“…The MSCs (cp. [23,24]) are positioned on both sides of the die [25]. The HFA-supply plate comprises six tactile flange draw-in sensors which measure the position of the flange edge during the forming operation.…”

A Tensile Specimen of Tailor Rolled Blanks with Equal Probability in Yield and Its Mechanical Behavior Analysis

“…They concluded that through optimizing the sheet thickness distribution of TRB, the maximum draw depth could be increased and the weight could be reduced. Kleiner et al [ 6 ] successfully manufactured a large-scale component optimized in regard to lightweight construction by utilizing high-pressure sheet metal forming in combination with the use of TRB. Chatti and Kleiner [ 7 ] manufactured a front cross member with two thickness transition zones and two crash boxes.…”

“…Chatti and Kleiner [ 7 ] manufactured a front cross member with two thickness transition zones and two crash boxes. The work of Kleiner et al [ 6 ] and Chatti and Kleiner [ 7 ] showed the feasibility of the further formation of TRB into complex components in cooperation with reasonable processes.…”