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smartform® – cost-optimized forming of high-strength steels without critical springback

New potential for weight reduction with unparalleled dimensional accuracy

Our new and innovative smartform® process allows the production of dimensionally accurate parts at lower cost by significantly reducing the amount of material used. At the same time it delivers greater degrees of freedom for complex geometric shapes.

smartform® is used in the press shop, i.e. at a central point in the production process where the geometry and structure of the vehicle are shaped. Here too the challenges are growing, because increasing material strengths lead to higher springback, reduced formability and a greater risk of variations between batches. With smartform® it is now possible to form high-strength steel grades reliably into highly accurate parts, opening up new weight-reduction potential.

Process - step 1

Pre-forming

  • Simple tooling design
  • No consideration of springback, but high cross-section repeatability
  • Robust and efficient forming process
  • Material allowance throughout cross section

Process - step 2

Sizing to final shape

  • Preform positioned in sizing die
  • Final sizing step triggers compressive stress superposition
  • Die corresponds to final part shape
  • Hardly any compensation measures required

Greatly reduced material usage compared with conventional processes

Compared with a conventional process, forming a longitudinal member with the smartform® process allows a significant reduction in trimming requirements. smartform® is the first process capable of using optimally shaped blanks with no flange, thus minimizing scrap. The previous measures to compensate for springback based on higher material usage are no longer necessary. On average, the weight of material used can be reduced by 15%.

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