FOCUS ON HYDROFORMING
FEA of the hydroformed component .
PAB Coventry specialises in heritage automotive , supplying manufacturers with components , panels , grilles , trim , instrumentation , brackets and associated parts . Part-funded by the Niche Vehicle Network ( NVN ), an independent network of niche vehicle manufacturers , PAB collaborated with the National Manufacturing Institute of Scotland ( NMIS ) to identify a new way to manufacture lighter-weight , large , complex vehicle components .
Tailored blanks ( TBs ) are semi-finished parts typically made from metal sheets with different alloys , thicknesses , coatings or material properties . Lightweight and low cost , whilst being resilient in crash tests , TBs were identified by PAB as key to reducing vehicle weight . However , many car components are complex , requiring TBs to be manufactured separately and subsequently joined , resulting in part deformation and wrinkling of the material .
The AFRC / PAB Coventry project looked to develop a hybrid hydroforming technology , combining hydroforming and tailored blanks . The AFRC conducted a Finite Element Simulation , which shows how a component or material reacts to specific influences . The process simulation is based on unique algorithms that determine approximate values using a complex combination of differential equations .
The Forming team determined how the proposed hydroforming solution would respond under different conditions and identified how to improve crashworthiness , strength and rigidity whilst also reducing weight and cost .
“ The research has provided a high degree of confidence within PAB that the proposed technology is technically and commercially feasible . The results predicted a component weight saving of 24 % and a reduction in material thickness of 18 % within existing material and design parameters ,” explained the AFRC .
“ This project also addressed the challenges of forming TBs with different properties , promoting weight savings through parts consolidation and reduced material usage . The project ’ s results also open the door for further manufacturing of complex-shaped components with greater material / design flexibility , presenting opportunities in other industries such as defence , aerospace and rail ,” it added .
“ It was great to collaborate with the AFRC
The results predicted a component weight saving of 24 % and a reduction in material thickness of 18 % within existing material and design parameters
on this hugely valuable study . A dozen additional structural and panel components were identified that could utilise the technology , thereby leading to further opportunities for weight reduction . The weight savings are expected to be optimised via further research and collaboration with design teams in the future ,” concluded Adam Malone , PAB Coventry .
Magnesium sheet forming
A separate AFRC project examined magnesium sheet forming potential using a novel hydroforming process variant .
The manufacturing industry is constantly searching for ways to reduce the number of components and create lighter-weight comparatively stiff and cost-effective structures for applications . Magnesium has received greater attention in recent years as it is much lighter by density , when compared to aluminium , and can generate significant weight savings in components . One of the major challenges of using magnesium in manufacturing is its poor formability at room temperature . Therefore , magnesium sheet material requires the use of hot forming processes ( such as superplastic forming ) to obtain complex shapes .
The AFRC recently identified a hydroforming technology development from Quintus Technologies , Sweden , known as highpressure warm forming ( HPWF ). This process development is understood to have significant potential to enable forming of a greater range of sheet material for aerospace , automotive and other applications .
A key challenge was to understand if this technology could provide an alternative , lower-cost method of manufacture to form magnesium sheet material for complex lightweighting applications . The project players also wanted to understand how the use of this material ( or material variants ) could further reduce the weight of aircraft and other vehicle structures and consequently have a positive impact on reducing carbon emissions .
Through the AFRC ’ s core research programme , the team conducted a high-pressure warm
Magnesium sheet ( General Motors ).
forming demonstrator project for Tier One Members , Boeing and Spirit AeroSystems . The project demonstrated the potential formability of magnesium sheet when using the Quintus Technologies equipment .
“ This project was delivered during the COVID-19 pandemic and was made possible by the truly collaborative and flexible approach that the AFRC and Quintus teams took to achieve demonstrator trials remotely and on time . The team proved the level of magnesium material formability improvement from room temperature up to a maximum system temperature capability ,” commented the AFRC .
“ The project outputs have shown clear benefits regarding material formability , such as producing complex shapes , and the significant costs savings that can be achieved using this new technology variant to form magnesium sheet . In this study , a cost comparison showed that up to 40 % cost savings could be made in producing this complex sheet component . This is compared to traditional methods such as superplastic forming ( SPF ), where high tooling costs and prolonged cycle times contribute to the higher overall cost ,” it added .
This information gives the companies involved more confidence in asking for magnesium sheet in future lightweight design strategies to further reduce body structure weight and , consequently , emissions .
Quintus Flexform™ , also called fluid cell forming , is a low-cost sheet metal forming process designed for prototyping and lower volume parts production .
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