07

2022

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12

Rolled parts for automotive lightweight


  Body weight reduction is an important part of automobile lightweight. Rolled parts are an important part of the body in white. This paper introduces the application and key technologies of roll forming in automobiles, and focuses on the prevention and solution of defects such as springback, deformation energy, deformation, side bending, and rollover in the forming of high-strength steel rolls. Developed a number of rolling products such as bumpers, bumpers, and thresholds.

Rolled parts

  Rolled parts for automotive lightweight

 

  In order to reduce energy consumption and environmental pollution, automobile lightweight has become a new trend in automobile manufacturing all over the world. The body-in-white is an important part of the car, accounting for about 40% of the total weight of the car, so the weight optimization of the body-in-white has become an important part of the lightweight design of the car. At present, in the development and design of the new body-in-white in the world, advanced high-strength steel plates are used, and a considerable part of them, such as the front and rear bumpers of the body, door beams, frame rails, roof brackets, B-pillars and chassis And other parts, are all completed by roll forming manufacturing method. The roll forming process is widely used in the manufacture of automotive parts. Many automotive components are produced using the roll forming process. Compared with the traditional stamping process, stamping forming technology has outstanding advantages such as high efficiency, material saving, environmental protection, and low cost, and has become one of the manufacturing methods of auto parts. According to statistics, the auto parts produced by the rolling process account for about 10% of the weight of the car.

 

  Auto parts produced by roll forming process

 

  Roll forming is to configure the forming rollers sequentially in multiple passes to continuously bend metal strips such as coils and strips to make profiles of specific cross-sections. Compared with other sheet metal forming processes, roll forming has the following advantages: high production efficiency, suitable for mass production, compared with stamping and bending processes, the efficiency is increased by more than 10 times, and the manufacturing cost is significantly reduced. The length of processed products is basically unlimited and can be produced continuously. The product has good surface quality and high dimensional accuracy. Other processes such as punching, welding, embossing, etc. can be integrated in the roll forming line. Compared with hot rolling and stamping process, it can save 15%~30% of material. Low production noise and no pollution.

 

  The profiles processed by the roll forming process have reasonable cross-sectional structures, various varieties and specifications, and accurate geometric dimensions, which reflect the modern society's requirements for lightweight, reasonable, and functional materials. Roll forming is an energy-saving technology, which is in line with the policy of "developing circular economy and creating a conservation-oriented society" in my country. Roll forming adopts advanced production technology to make the formed profile achieve better mechanical properties.

 

  Compared with ordinary carbon steel, high-strength steel has high yield strength and low elongation, which is determined by its structure, resulting in higher damage and more defects and springback during the rolling forming process. In recent years, through the combination of finite element analysis and intelligent optimization methods, according to the design parameters of complex processes, a more stable roll forming process and equipment optimization have been completed, and ideal results have been achieved.