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

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 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.

Research on formability of Tailor rolled blank in stamping process

“…Tailor Rolled Blank(TRB) was developped by Institute of Metal Forming(IBF) at Aachen University in Germany in the 1990s [1]. TRB is manufactured by a new kind of rolling technology-flexible rolling technology.…”

The shape analysis of three-dimensional flexible rolling method

“…The method of online optimizing control is applied in flexible rolling, which is producing parts with different properties from the blank with the same ingredient. Krux et al 2 controlled the roll gap in real-time to obtain the thickness shape of two-dimensional (2D) plates in the rolling direction by flexible rolling technology. The 2D formed parts can be obtained by using flexible rolling in the traditional rolling.…”