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Prototyping of automotive components with variable width and depth

Abeyrathna, Buddhika, Rolfe, Bernard, Harrasser, J, Sedlmaier, A, Ge, Rui, Pan, L and Weiss, Matthias 2017, Prototyping of automotive components with variable width and depth, in IDDRG 2017 : Materials modeling and testing for sheet metal forming : Proceedings of the 36th IDDRG 2017 Conference, IOP Publishing, Bristol, Eng., pp. 1-8, doi: 10.1088/1742-6596/896/1/012092.

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Title Prototyping of automotive components with variable width and depth
Author(s) Abeyrathna, BuddhikaORCID iD for Abeyrathna, Buddhika orcid.org/0000-0002-4476-3902
Rolfe, BernardORCID iD for Rolfe, Bernard orcid.org/0000-0001-8516-6170
Harrasser, J
Sedlmaier, A
Ge, Rui
Pan, L
Weiss, MatthiasORCID iD for Weiss, Matthias orcid.org/0000-0002-1845-6343
Conference name International Deep Drawing Research Group. Conference (36th : 2017 : Munich, Germany)
Conference location Munich, Germany
Conference dates 2017/07/02 - 2017/07/06
Title of proceedings IDDRG 2017 : Materials modeling and testing for sheet metal forming : Proceedings of the 36th IDDRG 2017 Conference
Editor(s) Volk, Wolfram
Publication date 2017
Series International Deep Drawing Research Group Conference
Start page 1
End page 8
Total pages 8
Publisher IOP Publishing
Place of publication Bristol, Eng.
Keyword(s) Flexible Roll Forming (FRF)
sheet metal forming
materials modelling
science & technology
technology
engineering, manufacturing
engineering
materials science
Summary Roll forming enables the manufacturing of longitudinal components from materials that combine high strength with limited formability and is increasingly used in the automotive industry for the manufacture of structural and crash components. An extension of conventional roll forming is the Flexible Roll Forming (FRF) process where the rolls are no longer fixed in space but are free to move which enables the forming of components with variable cross section over the length of the part. Even though FRF components have high weight saving potential the technology has found only limited application in the automotive industry. A new flexible forming facility has recently been developed that enables proof of concept studies and the production of FRF prototypes before a full FRF line is built; this may lead to a wider uptake of the FRF technology in the automotive industry. In this process, the pre-cut blank is placed between two clamps and the whole set up moves back and forth; a forming roll that is mounted on a servo-controlled platform with six degrees of freedom forms the pre-cut blank to the desired shape. In this study an initial forming concept for the flexible roll forming of an automotive component with variable height is developed using COPRA® FEA RF. This is followed by performing experimental prototyping studies on the new concept forming facility. Using the optical strain measurement system Autogrid Compact, material deformation, part shape and wrinkling severity are analysed for some forming passes and compared with the numerical results. The results show that the numerical model gives a good representation of material behaviour and that with increasing forming severity wrinkling issues need to be overcome in the process.
ISSN 1742-6588
1742-6596
Language eng
DOI 10.1088/1742-6596/896/1/012092
Field of Research 02 Physical Sciences
09 Engineering
HERDC Research category E1 Full written paper - refereed
ERA Research output type E Conference publication
Copyright notice ©2017, B Abeyrathna et al.
Free to Read? Yes
Use Rights Creative Commons Attribution licence
Persistent URL http://hdl.handle.net/10536/DRO/DU:30104531

Document type: Conference Paper
Collections: School of Engineering
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