Full process control for sheet metal forming
Customers of the automotive industry and other sectors are asking for more aluminium and steel options to meet increased specifications for strength and crash worthiness. To meet these requirements, new developments in sheet metal forming technology and manufacturing processes have emerged in recent years to build vehicles and consumer articles of reduced mass, but increased safety. Focusing on high-strength steels with increased formability for complex part designs, the INT-PULS-FORM project developed a novel pulsating blank holder system. This differs from conventional deep drawing in that the blank holder is subjected to a vibratory force. The metal flowing into the bottom die is thus improved, since frictional forces are reduced. In addition, a smaller punch force is required for the forming operation. Through full process control and special inlays for the drawing of high-strength steel new possibilities have opened up in terms of forming design and the use of less ductile materials. Furthermore, by controlling blank depth force an increase in the drawing depth was achieved. Usually, this is limited by the onset of wrinkling and fracture. The overall quality and strength of steel products was increased, while at the same time drawing stages were reduced. Application of multiple process control tools in the pulsating blank holder system can offer users significant cost-saving advantages, including reduction in energy consumption and the resulting emissions in the whole process. The developers seek technical collaboration with interested parties that can move the lab-scale tools prototype to the industrial level.
