Shape rolling

Shape rolling of profiles

Shape rolling is a forming process of bending using rotating tool movement (DIN 8586). Fraunhofer IWU has a shape rolling system with 9 profiling frames that can be arranged flexibly and whose output shafts are driven individually by servo motors. Shaping can be conducted with metal sheets up to a width of 500 mm. Our focus lies on integrating secondary operations (e.g. cutting operations, tempering) and on investigating sheet metal materials relevant for lightweight construction such as press hardening steels and magnesium wrought alloys. We create process designs using FEM, including the software COPRA, Abaqus and LS-Dyna.

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Research projects

Manufacturing of magnesium wrought alloys
Manufacturing of pipes with internal coating

Trends

Integration of secondary operations
Tempering in the shape rolling process
- Specific temperature management for processing materials relevant for lightweight construction
- Increase of the lightweight potential by using super high strength materials

Portfolio

Development of process chains

Market analysis
Investigation of process chains
Process optimization
Cost-benefit calculation
Development of manufacturing concepts
Planning and technological dimensioning of processes, tools and machines

Development and evaluation of forming strategies

Market analysis
Feasibility studies
Technology development
Development of characteristic process values and optimal forming strategies
Benchmarking
Numerical simulation
Manufacturing of prototypes

Quality assurance

Temperature monitoring
Control of component properties by analysis of geometry and strain

Equipment

Machine technology

Shape rolling system with 9 profiling frames
Siemens control allowing for arbitrary profiles of motion and acceleration
Tempering using induction systems or infrared systems

Software

COPRA RF and FEA RF^®
Abaqus
LS-Dyna