Roll forming systems for bodywork parts

Car body parts will be more cost effective with Dreistern roll forming equipment.

An ever increasing number of longitudinal members in mass-produced vehicles are roll formed components. The majority of these parts are produced on Dreistern roll forming systems. However, roll forming technology from Dreistern can also contribute to lowering costs and weight on other bodywork parts.

Dreistern offers advanced, flexible production concepts with the highest productivity for a whole series of bodywork components. Examples of these components are sill braces, cross-members, tunnel braces or roof racks. Ready-to-install assemblies made of high strength or ultra high strength steels or aluminium of impressive quality are the result. Roll forming is more suitable than other processes for processing high strength materials. The low tool costs are also impressive. This statement applies in particular to the manufacture of part variants. Length variants can even be realised without any additional tool costs at all.

 


Example machines / machine layout

  • Strip systems

    Strip systems are used for the continuous supply of the roll forming systems with the raw material, the flat strip.
    more
  • Pre and post-punching systems

    The integration of pre and post punching systems is particularly important for the manufacture of ready-to-install bodywork components.
    more
  • Roll forming section

    The heart of the system for the manufacture of bodywork components is the roll forming machine. Unlike other forming processes, roll forming is a continuous process.
    more

Strip systems

Strip systems

Strip systems are used for the continuous supply of the roll forming systems with the raw material, the flat strip. They not only make a contribution to the productivity of the overall system that should not be underestimated, but also to the quality of the components.

Coil changing times can represent significant sources of losses. Highly automated strip systems undertake a complete coil change in only 3 minutes, including welding together the ends of the strips. Precision straightening machines and low-stress strip feed to the downstream punching or roll forming machines provide the necessary conditions for the manufacture of precision components with very close tolerances. Depending on the nature of the requirements, the low-cost standard system can also be appropriate. Dreistern can also supply a matching strip system within a coherent overall concept.

Pre and post-punching systems

Pre and post-punching systems

The integration of pre and post punching systems is particularly important for the manufacture of ready-to-install bodywork components. It makes it possible to reduce the subsequent process steps and the related costs while improving the product quality at the same time.

Depending on the requirement, Dreistern realises concepts for the highest production performances or for extreme requirements in relation to flexibility and range of parts. In the first case this means production performances up to 80 parts per minute. In the second case re-tooling times of a few minutes. The number of punching operations that can be integrated here is practically unlimited. The Start-Stop® mode introduced by Dreistern has special significance here. The roll forming machine operates during this process like a precision roller feed that supplies the completely formed parts to the pressing and punching tools with high positioning accuracy.

Roll forming section

Roll forming section

The heart of the system for the manufacture of bodywork components is the roll forming machine. Unlike other forming processes, roll forming is a continuous process.

A special advantage is the high production speed. Even more important is often the low material consumption. Unlike manufacture using presses, the scrap is practically zero. A third, key advantage is the comparatively low tool costs. In the past roll forming was considered relatively inflexible due to long re-tooling times. Thanks to the new re-tooling technologies, roll forming systems from Dreistern are one of the most flexible manufacturing technologies used for bodywork components. 

Contact worldwide

Standorte Dreistern

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

Trade shows

23.10.18 - 26.10.18

EuroBLECH 2018, Hannover

Visit us at the EuroBLECH in hall 27, booth G60!

https://www.euroblech.com/2018/english/