The starting point of this study is the increasing number of variants with simultaneously decreasing batch sizes of body sheet metal components. The suppliers’ current production and plant technologies are increasingly reaching their economic limits. The SkaLaB joint project aims to provide economically viable solutions through scalable and flexible production processes and strategies. Car body sheet metal components have small-scale, locally distinctive yet characteristic geometries that realize the functional properties of the component. In production, secondary forming elements represent critical areas whose manufacture poses particular challenges and limits the flexibility and universality of the tools. A flexible and scalable tool system for the universal forming of sheet metal components is being developed for the separate production of secondary forming elements, independently of the main forming process. Within the scope of this work, individual groups of secondary forming elements are classified, and an order of these elements is created. In addition, a tool set for two particularly relevant secondary forming elements is designed and tested experimentally. Furthermore, a spring-loaded clamping system for rubber pad forming is developed, which enables a localized application of this process within a larger sheet metal blank.

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Design of a Flexible Tool System for the Scalable Production of Secondary Forming Elements

  • Michael Schiller,
  • Peter Frohn-Sörensen,
  • Martin Freitag,
  • Martin Manns,
  • Bernd Engel

摘要

The starting point of this study is the increasing number of variants with simultaneously decreasing batch sizes of body sheet metal components. The suppliers’ current production and plant technologies are increasingly reaching their economic limits. The SkaLaB joint project aims to provide economically viable solutions through scalable and flexible production processes and strategies. Car body sheet metal components have small-scale, locally distinctive yet characteristic geometries that realize the functional properties of the component. In production, secondary forming elements represent critical areas whose manufacture poses particular challenges and limits the flexibility and universality of the tools. A flexible and scalable tool system for the universal forming of sheet metal components is being developed for the separate production of secondary forming elements, independently of the main forming process. Within the scope of this work, individual groups of secondary forming elements are classified, and an order of these elements is created. In addition, a tool set for two particularly relevant secondary forming elements is designed and tested experimentally. Furthermore, a spring-loaded clamping system for rubber pad forming is developed, which enables a localized application of this process within a larger sheet metal blank.