Fraunhofer Institute for Machine Tools and Forming TechnologyWhat is the challenge?
Are you also facing declining quantities in the production of sheet metal components, causing established forming processes, e.g. multi-stage deep drawing processes, to become increasingly uneconomical due to the high tool costs? However, counter-strategies such as the use of common platforms and construction kits for several models and brands in the automotive industry - and thereby the artificial increase in the number of pieces through the multiple use of structural components - cannot be applied without restrictions.
What solution do we have for you?
We have developed a novel manufacturing method with StaBiFü® and have already proven its efficiency using the example of a seat cross-member. By redesigning the process steps - and the resulting simplification of the technology chain - a considerable part of the tool costs can be saved. Multi-stage, component-specific forming tools are reduced to a single stage. The remaining processing is carried out economically with flexible and standardised sheet metal processing systems as punch-bend-join production. Taking the seat cross-member as an example, the only remaining, shape-bound and thus component-specific forming stage was designed as a crash-forming process to save resources.
As a result, we have been able to reduce the required tool material by 90 percent and increase the degree of sheet metal utilisation from 60 to 77 percent. The energy and resource balance of the entire manufacturing process is thus significantly improved. In addition, the innovative manufacturing method has the potential to increase type and change flexibility in production and to shorten start-up times.
What is now available in concrete terms?
With StaBiFü® we offer you a solution approach for the design of alternative manufacturing process chains to flexibly produce sheet metal components in small to medium quantities. The cost-effectiveness of the method has already been convincingly demonstrated using the example of a seat cross-member. In principle, this can be transferred to other sheet metal components that are still manufactured today using multi-stage deep-drawing processes. We would be happy to check the technological feasibility and economic efficiency for your individual components and requirements.
Which partners were involved in the development?
- TRUMPF Werkzeugmaschinen und TRUMPF Lasertechnik GmbH
- TowerAutomotive
- Funding note: This research and development project was funded by the German Federal Ministry of Education and Research (BMBF) under the framework concept "Research for the production of tomorrow" (funding code: 02PO2250 ff) and supervised by the Project Management Agency Karlsruhe (PTKA)
