Continuous production of profiles with varying cross sections

The aim of this research project is the development of the technological foundations for the continuous production of profiles with cross sections which are arbitrarily varied in the longitudinal direction. The scope of design, which is enabled by a process combination of height-variable beading and roll forming, is to be explored.


The efficient use of material in production represents an important approach to the reduction of greenhouse gases. The great opportunity to achieve this is the development of production technologies, which can make an important contribution to cost-effectiveness, resource efficiency and environmental responsibility. Innovative processes, the use of custom-made semi-finished products and load-adapted component design enable the further development of the lightweight design potential of profiles. The most important manufacturing process for cold profiles is roll forming, which is currently restricted to profiles with a constant cross-section.


On the basis of a basic process understanding of the profiling of height-changing beads, a process design should be possible depending on the desired bead geometries. Based on this, the design and realization of a tooling system is targeted for manufacturing dimensionally accurate and error-free introduction of height-changeable beads.

Zielprofilbauteil mit höhenveränderlicher Sicke
Picture: PtU Bildarchiv
[1] Target profile component with height-variable beads


The manufacturing process is to be designed using FE calculations and with the results subsequently verified in experiments. The research project comprises four work packages:

1. Numerical analysis of process parameters

Investigations on the calibration principle, on the bending angle sequence or infeed, on bead geometry parameters, the sheet thickness as well as on the sheet material and the respective influence on the resulting bead geometry are the focus here.

2. Extension of the procedural limits

The aim is to increase the dimensional accuracy by means of process-side countermeasures on the one hand and by the use of additional components as part of a tool-side process enhancement on the other.

3. Designing and manufacturing of the tool system

4. Experimental investigations and comparison with the simulations


The research project is funded by the German Research Foundation (Deutsche Forschungsgemeinschaft DFG).