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Manufacturing of Long Products Made of Innovative Lightweight Materials

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Acta Metallurgica Sinica (English Letters) Aims and scope

Abstract

The processing of innovative lightweight materials to sheet metal components and assemblies with globally or locally defined properties is the object of this work. It takes a load-dependent design of components and assemblies, for example, based on the composition of different construction materials or a targeted setting of component areas with specified characteristics to fully exploit the lightweight potential when substituting conventionally used materials. Different process chains for the manufacturing of roll-formed long products made of magnesium alloys and high-strength steels with locally defined properties will be presented in this paper. Depending on the kind of material to be formed and the desired product characteristics, different temperature managements are needed for capable processes. Due to limited formability at room temperature, magnesium alloys require a heating of the forming zones above 200–225 °C throughout the bending process in order to activate additional gliding planes and to avoid any failures in the radii. The realization of local hardening effects requires at least one process-integrated heat treatment when roll forming manganese–boron steels. For both processes, it is imperative to realize a heating and cooling down or quenching appropriate for the manufacturing of long products with the required quality. Additionally, proper line speeds that allow a continuously operated economical production have to be considered. Research results including design, FEA, realization and experimentation of the mentioned process chains and strategies will be described in detail.

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Acknowledgments

The topics and results presented in this paper are majorly based on two research and development projects ‘TEMAKplus’ and ‘eniPROD’ which have received funding by the Federal Government of Germany and the Free State of Saxony namely within the programs European Regional Development Fund and Innovative Regional Growth Cores.

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Authors and Affiliations

  1. Fraunhofer Institute for Machine Tools and Forming Technology (IWU), Reichenhainer Str. 88, 09126, Chemnitz, Germany

    Karsten Richter, Roland Müller & Dirk Landgrebe

  2. Professorship Forming and Joining (UFF), Technische Universität Chemnitz, Reichenhainer Str. 70, 09126, Chemnitz, Germany

    Andreas Kunke, Verena Kräusel & Dirk Landgrebe

Authors
  1. Karsten Richter
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  2. Roland Müller
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  3. Andreas Kunke
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  4. Verena Kräusel
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  5. Dirk Landgrebe
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Corresponding author

Correspondence to Karsten Richter.

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Richter, K., Müller, R., Kunke, A. et al. Manufacturing of Long Products Made of Innovative Lightweight Materials. Acta Metall. Sin. (Engl. Lett.) 28, 1496–1502 (2015). https://doi.org/10.1007/s40195-015-0349-y

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  • DOI: https://doi.org/10.1007/s40195-015-0349-y

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