What is Geometric Adaptation of Hot Forming in Sheet Metal Forming?
Geometric adaptation of hot forming refers to the targeted adjustment of properties within a component to meet specific requirements. This allows properties such as strength and weight to be individually optimized. Three central methods make this possible in sheet metal forming:
- Tailor Welded Blanks (TWB)
- Tailor Rolled Blanks (TRB)
- Patch Blanks
Each of these techniques offers unique advantages and is suitable for different applications.
Tailor Welded Blanks (TWB)
Tailor Welded Blanks involve joining sheets with varying material thicknesses or grades. This can either be from the same material or from different materials, where the thickness can vary. The connection of the sheets is performed through laser welding of blanks or two coils.
Advantages of TWB
- Customized material combinations
- High flexibility in geometry
- Optimally adaptable to specific requirements
TWB is frequently used in the automotive industry. By connecting blanks or coils, components are created that are precisely tailored to their areas of application.
Tailor Rolled Blanks (TRB)
An alternative method for geometric adaptation of sheets is the use of Tailor Rolled Blanks (TRB). TRB is a flat rolling process where variable sheet thicknesses from the same material can be produced in almost any sequence along the rolling direction.
This enables thickness differences of up to 50% within a single component. TRB is particularly suitable for parts that are exposed to varying stresses along their length. Unlike TWB, no weld seams are introduced, which keeps the material structure intact.
TRB can be used for both cold forming and hot forming processes, offering a wide range of applications.
Advantages of TRB
- No structural changes caused by heat or welding after hot forming
- Compatibility with cold and hot forming processes
- Flexibility in thickness transitions (up to 50%)
This technique is particularly suitable for parts subjected to different loads along their length. TRB combines precision with versatility, offering a broad range of application possibilities.
Patch Blanks
Patch Blanks rely on the principle of localized reinforcement: small sheets (patches) are spot-welded onto a larger blank to provide additional stability or functionality.
Patch Blanks are manufactured in a flat state and then shaped through deep drawing. The advantages of Patch Blanks lie in the reduction of the number of parts, as the patch eliminates the need for additional reinforcements. This also reduces the required forming tools since separate tools for reinforcement sheets are no longer necessary.
Advantages of Patch Blanks
- Reduced number of parts and tooling costs
- Integration of reinforcements into the base structure
- Lower production effort
This method is ideal for saving weight and material without compromising functionality. Patch Blanks enable efficient manufacturing while simultaneously minimizing production costs.
Conclusion: The Future of Component Manufacturing
Geometric adaptation of hot forming through TWB, TRB, and Patch Blanks opens up new possibilities in sheet metal forming. With these processes, components can be developed that are perfectly tailored to their stress and function while simultaneously achieving material and weight savings.
By combining these techniques, solutions are created that meet even the highest requirements, making both the components and vehicles more efficient.
