At present, lightweight is an important development trend in the automotive sector, and OEMs need high-tech, cost-effective solutions to meet the market demand for both lightweight and safety. Compared with traditional stamping, the rolling forming process has the advantages of high efficiency, material saving, environmental protection and low cost, and is one of the manufacturing processes of automobile parts.
As an important part of the vehicle, the bodywhite accounts for about 40% of the total vehicle weight, so the weight reduction optimization of the body has become an important content of lightweight design. At present, advanced high-strength steel plates are widely used in the international bodywhite development and design of new models, of which a considerable part of the components, such as front and rear bumpers, door beams, frame rails, roof bow frames, B-pillars of the body and chassis, are manufactured by roll forming (Figure 1). According to statistics, the automobile parts manufactured by rolling process are about 10% of the weight of the vehicle.
As shown in Figure 2, the collision plate is a part that can maintain the interior space of the cab and reduce deformation after the car is subjected to a lateral impact. The part is made of dual-phase high-strength hot-dip galvanized steel plate by laser welding after roll forming, and is installed on the left and right front door. The anti-collision plate product requires the material to be laser welded after rolling forming. The section tolerance is ±0.1mm, the joint is required to be close, and the straightness of the joint point is less than 0.2mm.
Online laser welding is also widely used in new energy high-strength steel battery trays. In new energy vehicles, the weight of the power battery system accounts for 18%-30% of the vehicle, while the mass of the box accounts for about 10% to 20% of the total mass of the battery pack. Due to the current technical limitations of the battery itself, the battery pack tray, as the largest structural part of the power system, is the first target for engineers to study lightweight. Battery tray materials are mainly high-strength steel or aluminum alloy, but the cost of aluminum alloy tray is 2-3 times that of steel tray, and the carbon displacement from material to finished product is 5 times that of steel tray, so more and more manufacturers develop advanced lightweight high-strength steel and thermoformed steel battery tray instead of aluminum tray, and adopt advanced technology such as roll forming, thermoforming, laser welding, etc. Under the premise of improving the safety of the battery pack and the body structure, the height of the structure is reduced as much as possible, saving space and reducing the weight of the battery pack itself.
Figure 3 is a brand of battery tray under the box, the use of 1500Mpa and above ultra-high strength steel complex closed section. It has a variety of technology solutions for ultra-high strength steel rolling battery packs, including integrated solutions for rolling pressing and online laser welding. The innovative daily, mesh and complex deformation rolling sections are used in the battery housing.
In the future, Guosheng Laser will provide the laser equipment solutions with the most investment value for the automotive metal forming industry as the vision, continue to deepen the field of automotive lightweight laser equipment, follow the development trend of automotive lightweight manufacturing, increase research and development efforts, and provide users with one-stop laser solutions with continuous technological innovation and high-end quality products, giving automobile manufacturing more possibilities.