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Hydro-forming of conical steel profiles
The use of conical semi-finished products as base material for the internal high-pressure forming (IHF) process opens up to the automotive industry a wide range of possibilities with regard to the design flexibility of complex vehicle structures. In contrast to round tubes this enables the implementation of highly different ranges of panels while still maintaining high strength. The great potential of the IHF process in combination with conical tubes has been proved impressively in the NewSteelBody-Project (NSBŪ project) with the geometry of a side member.
In comparison with the reference structure a weight saving of 24 % was achieved together with higher stiffness while still completely fulfilling or even improving requirements relevant to safety and crash characteristics. Furthermore side members produced using the IHF process often show a more efficient material utilization and a very high dimensional accuracy in comparison to the reference structure.
An innovative solution has also been developed in the field of sealing technology of conical profiles. A sealing system adapted specially to the specific technical features of a conical profile enables a series-proven sealing function allowing significant supply distances.
 | FEM-Modell zur Herstellung des NSB® -Längsträgers aus konischen Stahlprofilen | |
 | Realbauteil des NSB® -Längsträgers | |
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