Cold roll forming in three dimensions. Cost effective and flexible production method for automotive parts as well as road safety barriers and posts

Cold roll forming is a metal forming process which is spread throughout the world today. In the cold roll forming process a flat sheet metal is progressively formed along a linear axis by sets of rotating rolls. The basic limitation of the roll forming process is mainly due to the fact that traditional roll forming machines have fixed rollers which limit the formed products to straight sections. The newly developed roll forming process uses high precision computer controlled and infinitely adjustable rollers in various directions to fabricated 3D shaped and variable profiled sections. In the automotive industry, structural body parts are generally made of steel via stamping. The structural and complexity potential of such parts is very high but investments and variable costs are significant. From a design point of view, cold roll forming is a near-optimal method of forming high-strength steels and consequently the automotive industry has a lot to gain from the newly developed 3D roll forming technique. This is mainly due to the fact that the implementation of high strength steels results in improved products by improving comfort, design, fuel consumption, safety and driving quality without increased costs. Potential cold rolled formed automotive parts may include the A and B pillars of vehicle cabins, which are often of curved shape, or different types of curved impact protection parts. These components are today made of extra-high strength (EHS) and ultra-high strength (UHS) steel. This technology is also a very applicable method for a cost effective production of road construction members. It will be much more economical to produce i.e. safety lightning posts. A prototype production unit will be built in Borlaenge, Sweden during the autumn 2006 (A). For the covering abstract of the conference see ITRD E212343.

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  • Publication Date: 2006


  • English

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  • Accession Number: 01102520
  • Record Type: Publication
  • Source Agency: TRL
  • Files: ITRD
  • Created Date: Jun 16 2008 7:52AM