Springback compensation for a vehicle’s steel body panel

Self Cite

Leading European manufacturers of profiles intended for the production of construction joinery currently use mainly PVC profiles with various configurations of external and internal shapes, allowing the production of functional products due to their intended use, shape, possibility of building them, maintaining color and maintaining low thermal transmittance coefficients of profiles. It is important to obtain high cross-sectional strengths, especially for torsion and bending. It is related to high wind loads of structures. A profile is made of a PVC with a low Young’s modulus compared to other materials, and thus it has low stiffness and strength indicators. This leads to relatively easy deformation of the joinery profiles during assembly. To avoid this unfavorable effect, the PVC profiles are reinforced with steel sections. Currently, in the industry producing PVC profiles, open steel reinforcement profiles are almost exclusively used. This solution is very disadvantageous for reasons of stiffness. However, manufacturers use such profiles primarily for technological and price reasons. Closed profiles pose many technological problems in their production and are approx. 30% more expensive compared to the corresponding open profiles. This paper presents research on the use of closed steel stiffening sections in place of open profiles. The main advantage of stiffening closed profiles is many times greater bending and torsional stiffness compared to open profiles. The theoretical and experimental studies carried out for selected cross-sections have shown that the stresses in a closed profile are several times lower than in an identical open profile, and the torsional stiffness of a closed profile is even several dozen times higher than that of an identical open profile.

Section: Analytical Researchmentioning

confidence: 99%

Influence of the shape of reinforcing window profiles on the strength and torsional stiffness of windows

Rejman

Bałon

Kiełbasa³

et al. 2022

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“…W celu weryfikacji wyników uzyskanych w symulacji komputerowej przeprowadzono praktyczne próby tłoczenia paneli zbiornika. Użyto półfabrykatów ze stali 1.4301 o grubości g = 0,5 mm [3,4]. Zaprojektowano i wykonano tłocznik pokazany na rys.…”

Section: Praktyczne Próby Tłoczeniaunclassified

Forming containers for PCM materials using a hydrotechnical method with an elastomer

Bałon¹,

Kiełbasa²,

Rejman³

et al. 2019

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In this work, the authors present the method of forming by oil exerting pressure on the elastic punch forming the shape of a container for phase change material (PCM). Thanks to the use of two elastomer plates with a hardness of 65 and 80 Shore, the obtained part has mapped stiffeners in the middle and the appropriate depth of the bowl. This method is not widespread due to the precise design ensuring tightness of the load system of the formed blank. By reducing the tool costs, this method is used in particular in the case of unit production of prototype parts or small production series. The authors carried out tests of mechanical properties of the material, numerical analysis of feasibility with the FEM, real (workshop) trials after previous optimization by trial and error through structural changes of the tool. This allowed to obtain the best material drawing parameters for given boundary conditions. The research allowed to eliminate significant stresses and thinning in finished parts and corners of PCM containers.

“…Niestety nowa geometria sprzyjała powstawaniu sprężynowania o wartości powyżej 2,8 mm (rys. 1) oraz dużej tendencji do fałdowania materiału [2]. Z tych powodów konieczne było przeprowadzenie wielu analiz tłoczności metodą na zimno ze szczególnym naciskiem na problem sprężynowania.…”

Section: Problemy Technologiczne Przy Tłoczeniu Na Zimno Mocno Obciążonych Elementów Samochodowychunclassified

Springback phenomenon of vehicle’s bumper in cold and hot forming methods

Bałon¹,

Świątoniowski²,

Rejman

et al. 2019

Self Cite

In order to meet the increasing requirements introduced by European Union directives and guidelines for the automotive industry, in the area of increasing safety while constantly reducing carbon dioxide emission limits, companies in the automotive industry implement new materials and new technologies for production. Currently, two trends are propagated in the way of manufacturing car body elements: the cold forming process of steel with a tensile strength Rm up to 1600 MPa and the hot forming process of steel with a strength Rm of up to 1800÷2000 MPa. The largest European manufacturers of car parts must meet the design and manufacture of hot forming tools. It is one of the most modern pressing technologies implemented for several years in innovative plants located both in Europe and the USA. Designing and testing of this type of tools are carried out by companies with advanced technological production capabilities. The use of this type of technology increases the level of product innovation, due to the know-how of companies for such complex tools, despite the fact that the costs of tools significantly exceed the costs of standard dies. The competition on the European market in the production of parts in hot forming process is not so large at the moment.