Structure building in crash performing car components

摘要

In the development of vehicle components, the decrease of material volume is intended for ecological and economic reasons. At the same time, the occupant protection is to be improved for crash-relevant components. This conflict, to produce lighter and lighter and at the same time stress-related components may range complex requirements, such as vehicle rails, by conventional methods, such as the introduction of a reinforcing plate or by Tailored Blanks can not be solved cost-efficient.A new procedure was developed to strengthen the areas of risk within the framework of the TFB 675 of the Deutsche Forschungsgemeinschaft. Two different forming technologies are here to influence the crash behaviour of the car component. The identification of critical deformation zones is supported by calculation using the finite element analysis /1,2/. On the one hand, secondary form elements are introduced by stretch forming into the sheet metal, whereby an increase in strength is achieved /3,4/. On the other hand, secondary form elements are introduced into the plate through burling by extrusion /5,6/ and thus control the deformation behaviour of the sheet metal during the crash. Both, the arrangement of the secondary design elements, as well as the expression of these were varied and evaluated in several experimental trials. By a suitable arrangement an optimal deformation behaviour of complex components could be achieved, as shown in Figure 1.