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

New potential for weight reduction with unparalleled dimensional accuracy with smartform^®

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.

smartform^® advantages at a glance:

Financially attractive: On average 15% more efficient utilization of material by using optimally shaped blanks, optional sheet thickness optimization and use of AHSS
High dimensional accuracy: Consistent quality thanks to virtually springback-free forming of high-strength steels independent of batch and tooling
High process reliability: Reduced machine downtimes in the press shop through fewer coil changes and reduced maintenance requirements
Efficient product start-up: Frontloading in the process development phase significantly reduces tryout work

smartform^® 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

smartform^® 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%.