Numerical research and optimisation of high pressure sheet metal forming of tailor rolled blanks

The high-pressure sheet metal forming of tailor rolled blanks allows the production of optimised components specially developed for their future function, which cannot be made from conventionally rolled sheet metal. The research aims at showing that the two processes, i.e. flexible rolling and high-pressure sheet metal forming, can be well represented in finite element simulations. By linking the finite element models with a combinatory optimisation tool it is possible to simulate and optimise the entire process chain and/or the product itself. Within this paper the forming restrictions of the high pressure sheet metal forming of tailor rolled blanks are presented. Furthermore, two optimisations, considering not only the process chain but also the behaviour under loading conditions, are shown.