3D_Flexible_Roll_Forming(柔性辊弯成型)
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3D “flexible roll forming” of profiles with discontinuous cross sections. A new production method for flexible and cost effective production of automotive components
Bandkantendehnung in %
limits of various kinds of material: Grenzwerte verschiedener Werkstoffe:
weiche Tiefziehstähle soft deep drawing steel
Flange Height Schenkelhöhe:
© 2011 data M SMS datam.de
www.autosteel.org
Strip Edge Strain in Flexible Roll Forming
50% 45% 40% 35% S 80 höherfeste Stähle High tensile steel S 60 S 40 30% 25% 20% 15% 10% 5%
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009)
• Flexible roll forming line for automotive parts (European R&D Project PROFORM; 2007-2010 with 23 project partners including Daimler and FIAT) • R&D of forming strategies (design and simulation) and hardware concepts
© 2011 data M SMS datam.de
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
www.autosteel.org
What is 3D Roll Forming?
© 2011 data M SMS datam.de
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
ww源自文库.autosteel.org
Concept of 3rd Generation: data M SMS (2011)
Patented self riding blank holder system
Patented Bipod-stands
• data M‘s new concepts for bipods and self riding blank holders
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
200 300 400 500 600 700 800 900 1000
0% 100
Transition radius of a flexible roll formed profile Übergangsradius eines flexibel gewalzten Profils
© 2011 data M SMS datam.de
© 2011 data M SMS datam.de
www.autosteel.org
Concept of 3rd Generation: data M SMS (2011)
BiPod (parallel kinematics) Technology in the Forming Stands
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Flexible Roll Forming Line (1998/ 2000)
• 1st try out line at PtU/ Germany • Concept of Prof. Schmöckel & Dr. Adrian Istrate
S100
ultra high tensile steel höchstfeste Stähle
Aluminium aluminum
Required: Design to match material and production process Adapted forming method(s)
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009) Simulation and Measuring of Warping Effects
• Warping and deviation effects of more than 5 mm ! • This is still too much for an industrial acceptance!
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009) Simulation and Measuring of Warping Effects
• Simulation shows warping effects (yellow and blue areas) clearly because of stretching and compression zones in the flexible rolled edges of the sheet
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009)
COPRA® AMC (Adaptive Motion Control) by data M SMS: • Integration of complete process chain (uncoiling, levelling, laser trimming, flexible roll forming, electromagnetic forming, inductive heating and cut off) • Easy user interface and programming of new shapes
www.autosteel.org
2nd Generation: data M SMS (2010)
© 2011 data M SMS datam.de
www.autosteel.org
2nd Generation: data M SMS (2010)
© 2011 data M SMS datam.de
www.autosteel.org
Start of Flexible Roll Forming (1998/ 2000)
• 1st try out line at PtU/ Germany • Concept of Prof. Schmöckel & Dr. Adrian Istrate • Feasibility of process proven but… • …still poor tolerances • COPRA® AMC (adaptive motion control) developed by data M SMS
www.autosteel.org
2nd Generation: data M SMS (2010)
• Warping effects could be significantly reduced compared to 1st generation
© 2011 data M SMS datam.de
Albert Sedlmaier
data M Sheet Metal Solutions (www.data-m.com)
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
www.autosteel.org
What is 3D Roll Forming?
Roll Forming of Profiles with discontinuous Cross Sections ( 3D Roll Forming, Flexible Roll Forming, … )
Bandkantendehnung in %
limits of various kinds of material: Grenzwerte verschiedener Werkstoffe:
weiche Tiefziehstähle soft deep drawing steel
Flange Height Schenkelhöhe:
© 2011 data M SMS datam.de
www.autosteel.org
Strip Edge Strain in Flexible Roll Forming
50% 45% 40% 35% S 80 höherfeste Stähle High tensile steel S 60 S 40 30% 25% 20% 15% 10% 5%
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009)
• Flexible roll forming line for automotive parts (European R&D Project PROFORM; 2007-2010 with 23 project partners including Daimler and FIAT) • R&D of forming strategies (design and simulation) and hardware concepts
© 2011 data M SMS datam.de
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
www.autosteel.org
What is 3D Roll Forming?
© 2011 data M SMS datam.de
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
ww源自文库.autosteel.org
Concept of 3rd Generation: data M SMS (2011)
Patented self riding blank holder system
Patented Bipod-stands
• data M‘s new concepts for bipods and self riding blank holders
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
200 300 400 500 600 700 800 900 1000
0% 100
Transition radius of a flexible roll formed profile Übergangsradius eines flexibel gewalzten Profils
© 2011 data M SMS datam.de
© 2011 data M SMS datam.de
www.autosteel.org
Concept of 3rd Generation: data M SMS (2011)
BiPod (parallel kinematics) Technology in the Forming Stands
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Flexible Roll Forming Line (1998/ 2000)
• 1st try out line at PtU/ Germany • Concept of Prof. Schmöckel & Dr. Adrian Istrate
S100
ultra high tensile steel höchstfeste Stähle
Aluminium aluminum
Required: Design to match material and production process Adapted forming method(s)
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009) Simulation and Measuring of Warping Effects
• Warping and deviation effects of more than 5 mm ! • This is still too much for an industrial acceptance!
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009) Simulation and Measuring of Warping Effects
• Simulation shows warping effects (yellow and blue areas) clearly because of stretching and compression zones in the flexible rolled edges of the sheet
© 2011 data M SMS datam.de
www.autosteel.org
1st Generation Line: PROFORM (2009)
COPRA® AMC (Adaptive Motion Control) by data M SMS: • Integration of complete process chain (uncoiling, levelling, laser trimming, flexible roll forming, electromagnetic forming, inductive heating and cut off) • Easy user interface and programming of new shapes
www.autosteel.org
2nd Generation: data M SMS (2010)
© 2011 data M SMS datam.de
www.autosteel.org
2nd Generation: data M SMS (2010)
© 2011 data M SMS datam.de
www.autosteel.org
Start of Flexible Roll Forming (1998/ 2000)
• 1st try out line at PtU/ Germany • Concept of Prof. Schmöckel & Dr. Adrian Istrate • Feasibility of process proven but… • …still poor tolerances • COPRA® AMC (adaptive motion control) developed by data M SMS
www.autosteel.org
2nd Generation: data M SMS (2010)
• Warping effects could be significantly reduced compared to 1st generation
© 2011 data M SMS datam.de
Albert Sedlmaier
data M Sheet Metal Solutions (www.data-m.com)
www.autosteel.org
Overview • What is 3D roll forming? • History of flexible roll forming for 3D-profiles • Results of recent research & development projects • data M‘s new concept to reach industrial accuracy • Benefits by light weight design of RF components • Why transitions with constant change of curvature? • Subsequent steps: laser welding & hydro forming • Future targets and outlook in 3D …
© 2011 data M SMS datam.de
www.autosteel.org
What is 3D Roll Forming?
Roll Forming of Profiles with discontinuous Cross Sections ( 3D Roll Forming, Flexible Roll Forming, … )