Roller Kiln Sheet Heating for Tailored-Property Auto Forming
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Solution Overview
Problem
Existing methods for molding complex-shaped metal components with varying mechanical properties are inefficient due to bulky and energy-intensive kilns, leading to undesired deformations and prolonged production times, which are not compatible with the automotive sector's requirements for reduced thickness and low energy consumption.
Innovation Solution
A method involving a refractory material kiln with a roller-shaped main body and electronically controlled heating elements that simultaneously heats multiple sheets to uniform temperature, followed by localized heating using a diode laser station, allowing for efficient and controlled temperature variations before forming, which reduces energy consumption and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If bulky kiln lines are used for heating sheets before forming, then uniform heating can be achieved, but energy consumption increases and production time is prolonged
Solution Approach 1:
The heating process is segmented into two distinct stages: (1) uniform heating of the entire sheet to a predetermined temperature using the roller-shaped kiln, and (2) localized additional heating of specific areas requiring different mechanical properties. This segmentation allows efficient bulk heating followed by precise local heating, reducing overall energy consumption compared to heating the entire sheet to maximum temperature.
Solution Approach 2:
The invention applies local quality by performing additional localized heating on specific areas of the sheet after uniform heating. This creates areas with different temperature histories and thus different mechanical properties in the final component, while avoiding the energy waste of heating the entire sheet to the same high temperature.
2Temperature
If traditional kiln lines are used for sheet heating, then heating can be performed, but construction time increases and production efficiency decreases
Solution Approach 1:
The kiln is designed with a roller-shaped main body that can rotate around a longitudinal axis, dynamically adjusting the position of sectors relative to inlet and outlet ports. This dynamic configuration allows flexible loading and unloading of sheets, optimizing the heating process and reducing construction time compared to static traditional kiln lines.
Solution Approach 2:
The roller-shaped kiln enables continuous processing by maintaining sheets in the heating zone for the required duration through rotation, allowing seamless transition between loading, heating, and unloading operations. This continuous action eliminates idle time and improves production efficiency.
3Temperature
If localized cooling is applied during moulding, then specific areas can be cooled, but undesired deformations occur in certain component areas
Solution Approach 1:
The invention performs preliminary localized heating of specific sheet areas before forming, creating controlled temperature differences that influence material flow and mechanical properties during subsequent forming. This preliminary action prevents the need for localized cooling after forming, thereby avoiding the deformations that would result from post-forming cooling.
4Weight of moving object
If sheet thickness is reduced to meet automotive sector requirements, then component lightness increases, but forming capability and mechanical property control become more difficult
Solution Approach 1:
The invention changes the temperature parameter distribution across the sheet thickness and area before forming. By creating controlled temperature differences in thin sheets through selective heating, the material exhibits enhanced formability and controlled mechanical properties during forming, enabling successful processing of reduced-thickness sheets that would otherwise be difficult to form with precise mechanical property control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of complex-shaped components with localized mechanical property variations, achieving reduced thickness and lightness without additional reinforcing elements, while ensuring compatibility with automotive sector production rates and energy efficiency.
Implementation Method 1
a plurality of heating elements incorporated in said roller-shaped main body configured to heat said roller body, in such a way that the main body with a roller shape is arranged to heat said plurality of sheets, at their areas in contact with said roller body
Implementation Method 2
carrying out an additional heating step following extraction of the sheets from the kiln, wherein the sheets are locally heated only at one area, so as to obtain sheets with areas heated to different temperatures
Data Source
AI summary
A method for moulding a sheet into a component of complex shape having areas with different mechanical properties, particularly a motor-vehicle component, includes a first heating step of the sheet carried out by a kiln, prior to forming the component. The kiln has a main body with a roller shape, having a plurality of sectors extending along a radial direction with respect to a longitudinal axis of the roller body. The sectors are configured to each receive a sheet, so that the main body with a roller shape is arranged to simultaneously carry a plurality of sheets. The kiln includes a plurality of heating elements incorporated in the roller-shaped main body, so as to heat the sheets in contact with the roller body. The kiln includes at least one electronically-controlled drive motor, arranged to rotate the roller-shaped main body around the longitudinal axis of the kiln, so as to vary the position of the sectors with respect to the inlet and outlet ports. An additional heating step follows extraction of the sheets from the kiln, wherein the sheets are locally heated only at one area, so as to obtain sheets with areas heated to different temperatures.