Flexible manufacturing processes for the production of tube drawn profiles with functional elements

The manufacturing of automotive parts is required to keep up with
the evolution of geometrical features and used materials. The mass
production of such parts requires several intermediate steps in order
to achieve the demanded complex geometries. Merging two of such
steps shows a large efficiency potential, but at the same time requires
a thorough research. In the scope of this thesis a combined drawing
and rolling process is developed. The focus is laid on production
speed, compatibility with a drawing step and a large target geometrical
family of products. Possible concepts are searched and a best fit
is determined. Material characteristics as well as process parameters
are experimentally acquired. FE models of the process are created and
a prototype is validated through experimental try-outs. Geometrical
and force deviations are analysed and the models adjusted. Based on
the validation, a mapping of feasible operating points is performed for
the pilot plant. With this outcome, it becomes possible to assess the
feasibility of target geometries and deliver process recommendations.
This thesis covers the concept development and simulations, the tool
design and experiments as well as the FEM validation, the creation of
process windows with a geometry correction possibility as well as a roll
design optimization given a specific target product.