Roll forming systems for front and side impact protection

Roll forming is excellently suited to the manufacture of ready-to-install lightweight parts for front and side impact protection. A special advantage is in the economical processing of ultra high strength steels.

High requirements in relation to stiffness are placed on profiles for front and side impact. Often such profiles are designed as welded hollow profiles. Depending on the requirements and profile cross-section, laser welding or spot welding is used. The roll forming process offers ideal prerequisites for good and therefore quick welding. At 8 to 15 m/min the welding speeds that can be obtained are way above the speeds that are otherwise common in bodywork manufacture. Profiles for front and side impact protection almost always have a bend around the longitudinal axis. Due to an integrated bending unit, any radius can be realised, within certain limits. A change in the bending radius only signifies a change to the adjustment of the bending tool and is therefore not related with any tool costs. Right and left-hand versions of components can also be manufactured with the same roll forming tool, therefore they do not cause any additional tool costs. Often a single product does not fully exploit the capacity of a highly productive Dreistern roll forming system. In such cases several, very different components are often produced on a system. This is not a problem with highly flexible quick change concepts from Dreistern.


Example machines / machine layout

  • Manufacture of laser-welded bumpers

    The manufacture of laser-welded bumpers from high strength steels requires special...
    more
  • Combined manufacture of laser-welded sill reinforcements and bumpers

    The ability of Dreistern roll forming systems to produce significantly different products on one system is demonstrated by this machine example.
    more
  • Manufacture of spot-welded sill reinforcements

    The laser plays an important role in the manufacture of components for front and side impact protection.
    more

Manufacture of laser-welded bumpers

Manufacture of laser-welded bumpers

The manufacture of laser-welded bumpers from high strength steels requires special know-how on the part of the machine supplier in the area of forming technology, welding, bending and finally cutting to length.

Thanks to years of experience in the processing of ultra high strength materials, Dreistern has the necessary knowledge to be able to realise such systems without risk. The forming technology is precisely matched to the material. The selection of the correct type of laser and suitable welding parameters, and also the design of the cutting technology is an important prerequisite for meeting the high requirements on safety-related components.

Combined manufacture of laser-welded sill reinforcements and bumpers

Combined manufacture of laser-welded sill reinforcements and bumpers

The ability of Dreistern roll forming systems to produce significantly different products on one system is demonstrated by this machine example. A special challenge in this project was the very different requirements on the punching technology.  

At the same time the requirement for short re-tooling time had to be met. The Dreistern engineers made use of a particularly clever trick here. A component with the punching system for the bumper is mounted on rails and can be moved in and out of the machine in a very short time. The window brace in this example was previously designed as a two-piece pressed part that was given its final form in a separate joining operation. By using roll forming technology it was possible to remove the welded flange. The result was a significant weight reduction with a simultaneous reduction in part costs.

Manufacture of spot-welded sill reinforcements

Manufacture of spot-welded sill reinforcements

The laser plays an important role in the manufacture of components for front and side impact protection. However, it is certainly not always the only solution. The special form of this window channel brace permits low-cost spot welding.

The investment costs for the spot welding unit are less than 50% of the costs of a laser. Dreistern demonstrated in this example that spot welding is not inferior to the laser in relation to speed. By using rotating welding electrodes it was possible to achieve a production speed of 12 m/min in this case. Another striking aspect is the fact that this Dreistern customer was able to win the Swedish Steel Prize with this component

Contact worldwide

Standorte Dreistern

Tel.: +49 (7622) 391-0
Fax: +49 (7622) 391-200
E-Mail

Trade shows

19.09.18 - 23.09.18

Metalworking and CNC Machine Tool Show 2018, Shanghai

 
23.10.18 - 26.10.18

EuroBLECH 2018, Hannover

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In order to remain successful, the permanent development within our own core competencies and beyond is of great importance to our customers and to Dreistern itself. In this way we guarantee economic efficiency and investment security paired with uncompromising quality and high technology standards.

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