Authors: Eguia, I.
Gutiérrez, Ma. A.
Iturbe, R.
Mangas, A.
Title: Electromagnetic Forming of Longitudinal Strengthening Ribs in Roll Formed Automotive Profiles
Language (ISO): en
Abstract: In the automotive industry, increasing ecological concerns and demands for higher performance have become lightweight construction a key aspect. Due to the gradual introduction of high strength materials on the one side, and greater consideration with regard to continuous manufacturing technologies on the other side, it is possible nowadays to address the demands that structural and complex automotive parts have to face, from the standpoint of lightweight manufacturing. Thickness, shape and impact conditions constitute the main aspects to consider for such parts and shape conditions in particular require from complex, costly and lengthy procedures, especially when discontinuous forming operations such as stamping and hydro forming procedures are selected. However, continuous forming operations like Roll Forming (RF) can prove to be advantageous and suited for scalable parts (e.g in length) and at the same time be economically reasonable. RF lines as well generally incorporate additional installations to perform multiple forming operations destined to imprint strengthening ribs perform punching operations or weld certain parts. It is in this context where the usefulness of the electromagnetic forming technology for completion of auxiliary operations can be proven, given its flexibility and reasonable investment costs. Electromagnetic forming (EMF) is a contact-free technique where large forces can be imparted to a conductive metallic workpiece by a pure electromagnetic interaction. The produced electromagnetic pressure can produce stresses in the workpiece that are several times larger than the material flow stress. Ultimately this can cause the workpiece to deform plastically and to be accelerated achieving high velocities. Once the velocity is imparted to the workpiece, the shape can be developed either by free or die forming. The work described in this paper explores the potential of the EMF process to adequately form shallow longitudinal ribs or stiffeners in components previously formed utilizing an innovative concept called Flexible Roll Forming, developed at The Technical University of Darmstadt in Germany, by means of magnetic pulse forming, maintaining the integrity of the workpiece while trying to meet industry standard tolerances. Profiles exhibiting hat-like cross sections made of AHSS steels were subjected to localized impulses in order to achieve strengthening features in the roll formed part. ZStE340 steel alloy profiles were first roll formed and then inserted in the EM forming installation designed for the occasion. A high strength copper alloy (Cr-Zr-Cu) was used as a conductor for the single turn coil, placed opposite to the sidewall in the moment of the energy delivery. Formed specimens were subsequently measured to account for existing dimensional deviations.
Subject Headings: finishing
Issue Date: 2010
Provenance: Institut für Umformtechnik - Technische Universität Dortmund
Is part of: 4th International Conference on High Speed Forming, March 9th-10th 2010 Columbus, Ohio, USA
Appears in Collections:ICHSF 2010

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