PRODUCTION OF LONGITUDINAL COMPONENTS BY COMBINING FLEXIBILE ROLL FORMING AND FREE FORMING

To investigate the feasibility, cost and time saving potential of manufacturing full part families of BIW structural members via Flexible Roll Forming (FRF) in combination with 3d Free Forming for rapid prototyping and low volume production runs.

The combination of modified FRF with 30 Free Forming may overcome the part complexity restrictions currently limiting implementation of FRF in automotive production. Ford Global's 3D Free Forming facility allows parts of high complexity to be produced but with limited size and at low production rates; this restricts the process from being used for rapid prototyping and production runs.
Combining both technologies to pre-form large components by FRF followed by shaping small and complex regions with Ford's Free Forming unit may present a time and cost effective solution for rapid prototyping and low volume production runs. Modified FRF will  permit the reasonably rapid forming of overall shape in long parts such as pillars, rocker reinforcements, roof rails and also changes necessary for regional platform derivatives providing an enabler for GCBP fficiency.