Manufacturing system for the integrated hydroforming, trimming and welding of sheet metal pairs

“…During manufacturing, it is essential to achieve product accuracy and to follow and specify structural properties by means of computational methods [3][4][5]. Furthermore, manufacturing processes and production systems can be pre-designed and optimized prior to prototype production for the needs of the production lines with the support of virtual simulative manufacturing chains.…”

Section: Background and Motivationmentioning

confidence: 99%

Simulation of the manufacturing process chain of welded frame structures

Zaeh

Papadakis

Langhorst

2008

Prod. Eng. Res. Devel.

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Numerical solutions of manufacturing process chains strongly focus on supporting the production of frame structures in the vehicle industry. Frame structures play a central role in all means of transportation, dominating the total mass in automobiles, trains, airplanes, and even space ships. In the case of automobiles, the frame structure mass constitutes about 30% of the total mass. In the case of the automotive industry, the mass-production, the high-quality standards and the need for mass minimization all increase the necessity to apply virtual manufacturing methods in the production cycle of frame structures. In scope of this paper, a method of chaining the numerical analysis of the structural effect on frame components during successive manufacturing processes is introduced. The change of thermal, metallurgical, and mechanical properties in structures during manufacturing is analyzed by applying theoretical models depending on the identified problem.

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“…Among the strategies employed for lightweight BIW design are (1) low-density material substitution (aluminium, magnesium and thermoplastics are the most common candidates) [2,3]; (2) manufacturing process improvement ( an array of new manufacturing techniques are being adopted by the automotive industry, such as hydro-forming, stamping of Tailorwelded blankets, etc.) [4,5]; and (3) design architecture optimization (FE and sensitivity based optimization provides a promising way to reduce BIW weight, for example) [6][7][8][9]. The availability of advanced high-strength steel (AHSS) is emphasized as an emerging technology that would help reduce vehicle weight by allowing the use of reduced-gauge underbody parts.…”

Section: Introductionmentioning

confidence: 99%

Improving Stiffness-to-weight Ratio of Spot-welded Structures based upon Nonlinear Finite Element Modelling

Zhang

2017

IOP Conf. Ser.: Mater. Sci. Eng.

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Abstract. Spot welding has been widely used for vehicle body construction due to its advantages of high speed and adaptability for automation. An effort to increase the stiffnessto-weight ratio of spot-welded structures is investigated based upon nonlinear finite element analysis. Topology optimization is conducted for reducing weight in the overlapping regions by choosing an appropriate topology. Three spot-welded models (lap, doubt-hat and T-shape) that approximate "typical" vehicle body components are studied for validating and illustrating the proposed method. It is concluded that removing underutilized material from overlapping regions can result in a significant increase in structural stiffness-to-weight ratio.

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Manufacturing system for the integrated hydroforming, trimming and welding of sheet metal pairs

Cited by 24 publications

References 2 publications

Process chain modeling and selection in an additive manufacturing context

Process chain modeling and selection in an additive manufacturing context

Simulation of the manufacturing process chain of welded frame structures

Improving Stiffness-to-weight Ratio of Spot-welded Structures based upon Nonlinear Finite Element Modelling

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