Simultaneous Forming and Joining by Linear Flow Splitting - From Basic Mechanisms to the Continuous Manufacturing Line

Abstract

Abstract The public demand for an efficient and sustainable use of energy resources has led to a more consequent use of lightweight constructions. In the automotive sector for example, weight reduction is achieved by a structural construction with branched parts by reinforcing ribs or by a combination of materials with different strengths. To join these assemblies, different joining by forming processes are used. Mostly forming and joining takes place in separate processes. The innovative forming technology of linear flow splitting offers advantages with regard to the production of lightweight parts and the joining by plastic deformation at the same time. Residual stresses in the manufactured profiles are used in the linear flow splitting process for an additional mechanical joining of profiles and other parts. Here, the forming and mechanical joining zones do not coincide, which is different to conventional joining technologies. The study at hand presents the tensile joining mechanism in the forming process of linear flow splitting in detail and shows the implemented manufacturing line for simultaneous forming and joining in the process of linear flow splitting.