Manufacturing of multi-chambered profiles by integration of forming, cutting and joining processes
At present, multi-chambered lightweight profiles are made predominantly by extrusion of aluminium alloys. However, steel materials are not economically extrudable. Furthermore, roll-formed multi-chambered profiles are only producible with material laminations. Bifurcated profiles are producible by linear flow splitting. Currently, machine concepts for the flexible production of these profiles are missing.
For the continuous production of multi-chambered profiles made of steel, a roll-forming machine offers a good basis for the integration of different processes such as forming, high speed cutting, joining and separation. Currently the processes mentioned are realized separately. Thus the combination of forming, cutting and joining processes are not state-of-the-art. Thereby, investigating the influence of the processes among each other in a flexible arrangement as well as in varying process chains is of special interest.
The main objective of this subproject is to manufacture multi-chambered profiles out of steel, while integrating all processes mentioned on a reconfigurable machine in a complete process chain. A variation of the process arrangements allows the production of different profile types using the same machine. In addition, methods were developed in order to determine the optimal process chains.
The following steps for the development of optimized process chains are planned:
- Analysis of each process and reciprocal effects among themselves
- Representation of possible process arrangements and the interaction of each process in models
- Development of mathematical formulation of the material flow with consideration of the processes
- Deflection of recommendations of process sequences with respect to the subsequent profile characteristics
- Development of a machine concept
- Manufacturing of profile prototypes