Ditzingen, Germany, January 12, 2010 – If automotive manufacturers use universal sheet metal processing systems in their production halls instead of mechnical press systems, they could make their assembly process considerably more flexible while reducing costs. "The basic idea behind this concept is that the components for production are produced, formed and subsequently welded from smooth metal sheets using 2D laser cutting machines," explains Klaus Löffler, a TRUMPF specialist in automotive production technology.
Automotive manufacturers are currently facing a multitude of challenges. On the one hand, they have to comply with the legal requirements for the CO2 emissions of the cars they produce. On the other hand, customers are demanding more and more of their cars. Current trends point to built-to-order cars that automotive manufacturers have to launch on the market in ever shorter product cycles. This also reduces the quantities in production during the service life of the car.
In order to face these challenges, automotive manufacturers have to adapt their production accordingly and become more flexible. "Traditional production methods that use mechanical press systems to produce deep-drawn parts are becoming less and less suitable for this purpose," says Löffler. One way to make production workflows more flexible and meet customer and legal requirements is to use universal production equipment such as sheet metal processing machines. Components are produced by first cutting the blanks in the laser cutting machine, then forming them in the bending machine and, finally, welding them using the laser systems. "Overall, the automotive manufacturer can reduce component costs considerably using this concept compared to conventional methods," says Löffler. Just-in-time production used where the components are needed eliminates logistics costs because transport and storage are no longer needed. Since the automotive manufacturer works with universal sheet metal processing tools, it can upgrade the entire production system to the new series faster when replacing models; sometimes only changes in the machine software are needed.
The use of lasers, which are key to this production method, considerably lowers the costs per component. "Even using the laser to cut blanks allows the material to be better utilized. The scrap from a window cutout, for example, can be used for other components," adds Löffler. This means that the usual material utilization quota of 50 percent can be increased to more than 80 percent," he says. And by using combined punch-laser systems, automotive manufacturers can integrate additional features such as thread-tapping, angles, louvers or brackets directly onto the component – without additional joining steps. This reduces the number of components, saving material and lowering weight and costs.
"The potential of the process chain can be further exploited if laser welding is used instead of resistance spot welding," explains Löffler. This process makes it unnecessary to overlap materials; instead flangeless components are attached. This improved material utilization results in completely new opportunities in lightweight design. The new production system has already passed the test phase among several automotive manufacturers and will be used to produce structural components such as panels, longitudinal supports, seat frames and other similar components. Even in motor sports, sheet metal processing systems have already proven their value.
TRUMPF works with its customers in automotive manufacturing from the start in helping them tap into the potential of sheet metal processing systems. They are given a comprehensive product program with production equipment for flexible sheet metal processing for punching and forming, energy-efficient laser beams and modular laser systems for cutting and welding. In addition design workshops, courses on teaching application skills as well as product training classes help manufacturers make even greater use of the savings and quality potential of the new methods.
About TRUMPF
With sales totaling US $ 2.28 billion (€ 1.66 billion) and about 8,000 employees (preliminary figures for the 2008/09 fiscal year), the TRUMPF Group ranks among the leading manufacturing companies worldwide. The three following business divisions are combined under the umbrella of a holding company: Machine Tools/Power Tools, Laser Technology/Electronics and Medical Technology. Its core business are machine tools for flexible sheet metal processing for punching and forming, laser processing and bending. In the field of industrial lasers and laser systems, the company is the technological leader on the world market. With about 50 subsidiaries and branch offices, the Group is represented in almost every European country, in North and South America as well as in Asia. Production locations can be found in Germany, Austria, China, Czech Republic, France, Great Britain, Japan, Mexico, Poland, Switzerland and the USA.
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