TPT January 2007

Technology Update

Advanced manufacturing technology for lightweight automotive parts

ThyssenKrupp Steel AG, Germany, has developed new technology for manufacturing weight- and cost-optimised tubular components for cars, and has recently put into operation a pilot press which shortens the manufacturing route for tubular parts. The new machine is based on the ThyssenKrupp Steel-developed T 3 technology. It works like a four-column press, has an integrated laser welding head and forms tubular parts from flat blanks in a single operation. Parts can be made with varying cross sections and with secondary design features. Tubular body and chassis parts are regarded as the key to automotive weight reduction, because unlike conventional stamped and welded parts, they do not require welding flanges. They are also more resistant to torsion and better utilise existing space. ThyssenKrupp Steel has created three generations of Thyssen Tailored Tubes, all made from flat blanks and longitudinally welded by laser.

The blanks can have different thicknesses, strengths and coatings, allowing them to be precisely tailored to the load conditions in the finished part. With the latest tubes, the cross section can vary over the length of the component, eg changing from cylindrical

› ThyssenKrupp Steel’s new technology will assist in the production of lighter car components

180mm. Previously cut blanks are shaped into tubes in two or more dies, and then welded by laser. To produce varying cross sections and secondary design features the blanks are formed against a correspondingly shaped core. Additionally (or alternatively) prior to curling the blank can be pressed into a bottom die by means of the core to shape the part. The press develops a total tonnage of up to 1,600t, including 1,000t on a single axis, allowing it to process even high-strength steels. Parts can be positioned in four directions simultaneously, with an accuracy of between one and five hundredths on each axis. The machine will also be used as a tryout press for future high-volume machines. ThyssenKrupp Steel AG – Germany Fax : +49 203 52 25 102 Website : www.thyssenkrupp-steel.de High saw-cut quality with new CNC tube cutting systems New-Form Tools, Canada, has expanded into the CNC tube cutting machinery market with a new CNC tube cutting system. Utilising a shear-cut operation, these tube cutting systems are designed for steel tubing although can be adapted to cut stainless steels, high tensile and regular carbon steels. fi The new CNC tube cutting system from New-Form Tools

to conical, to triangular or rectangular. In addition, secondary design features such as recesses or projections can be integrated. The parts are so close to net shape that car manufacturers can eliminate complete manufacturing steps. The complex process of hydroforming, currently used to give tubular parts their final shape, can be dispensed with in many cases. Compared with conventional stamped and welded parts, tubular components are at least cost-neutral, and offer a weight saving of up to 26 per cent. The new pilot press can manufacture all types of Thyssen Tailored Tubes up to a length of 3m and an equivalent diameter of

Automatic cutting and bar end-working machines Sinico SpA, Italy, specialises in the design and manufacture of automatic rotary transfer cut-off and end-finishing machines, suitable for producing medium and large series of metal parts from tubes, bars, coils, forgings and blanks.

The company’s end-finishing machines can carry out operations such as facing, chamfering, centring, turning, drilling, threading, tapping, milling, grooving and splining. In addition, these machines are also designed for shaping operations such as flaring, tapering, rolling, pressing, marking and knurling. Sinico machines can handle all metal materials (including

› Sinico produces a range of automatic rotary transfer cut-off and end-finishing machines

steel, stainless steel, aluminium, copper, brass, titanium and inconel), and all operations are carried out in one chucking. Depending on the machine model and material to be handled, general machining capacities range from 3-120mm Ø, and from 10-640mm in length.

Sinico SpA – Italy Fax : +39 0444 644 855 Email : sales@sinico.com • Website : www.sinico.com

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J ANUARY /F EBRUARY 2007