European RTD project PROFORM

 

The company EXIMET TRAFO, spol. s r.o. is a member of International consortium, which solves an ambitious RTD project PROFORM since November 2006. The project is proposed for four years with the budget of 10,1 million EUR, whereof 60 % is contribution from European Commission within the EU Framework Programme for support of research and technological development (FP6) and its priority Nanotechnology and nanosciences, knowledge-based multifunctional materials and new production processes and devices.

Consortium of partners

The consortium is integrated by 24 partners from 6 countries providing a wide European dimension and added value on scientific and technological, innovation, training and on the integration and strengthening the ERA and to European standards. The consortium covers the whole “value-chain”: from knowledge production and technology development to their transfer; from the lower end of the value chain, auxiliary suppliers (Actarus, Eximet, Antec, LMB, AXYAL, TRIBOtech, Genta, DATA-M), production system/equipment/tool suppliers (Ingemat, Onapres, Numalliance, Gasparini), component manufacturer (GBN) to large module/system producers (Gestamp, Dura) and car manufacturers (Fiat, Daimler Chrysler).

Structure of consortium:

Role of EXIMET TRAFO spol. s r.o.

EXIMET TRAFO spol. s r.o. is the one of 14 small and medium enterprises, which are integrated in the project PROFORM. Due to the EXIMET’s long-term experience and strong development facilities, the company was put in charge of development; testing and special ultraconductive coils production.
To successful involvement of EXIMET TRAFO in integrated PROFORM project significantly contributed consulting company Inova Pro, s.r.o. European Commission assessed this kind of collaboration as „best practice“.

Project mission

PROFORM objective is to develop a new engineering and manufacturing concept, PROFILE FORMING, based on a built to order system for reducing lead time and costs in producing high technology transport components for chassis and vehicle bodies. The concept is based on the integration of three emerging forming technologies (roll forming RF, laser forming LF and electromagnetic forming EMF) conceived in the frame of a simultaneous engineering and production strategy.

Schema of manufacture concept:

Project benefit

The development, research and innovation work performed on the three forming process and on the simultaneous engineering for the integrated production, will be followed by proof of concept deliverables consisting on industrial prototypes with its processes (cadences, cleanness, robustness…), functional (weight, quality…) and cost analysis (cost per unit, initial investment, raw material, scrap…) that will quantify the feasibility
The objectives of the project contribute to a large economic development, social achievements and environmental benefits in addition to the more commercial ones expected, the last (but not least in importance) goal being the contribution to the sustainability of the well- being of social agents. In particular it will contribute to:

• Reduction of fuel consumption.
• Preservation of natural resources: A reduction in weight leads to a relevant preservation of natural resources.
• Increase vehicle safety and reliability due to the increased stiffness and quality of the parts.
• Improvement in the quality of life of European citizens as consumers.

Project specific objectives

The main objective of the PROFORM project´s proposal is to develop a new engineering and manufacturing concept based in a built to order system for reducing lead time and costs in producing high technology transport components for chassis and vehicle bodies.
To achieve this main objective the following partial objectives need to be addressed:

• Development of a flexible roll forming technology for the production of high technology components for automotive body structures
• Development of efficient electromagnetic forming technology exploiting the emerging capabilities in the area of new/nano materials and multifunctional materials
• Development of an efficient laser forming technology for the production of vehicle body structure from roll forming semi-finished parts
• Development of a simultaneous engineering strategy for the design and production of components for body in white based on roll forming semi-finished parts customized with EMF and LF technologies.
• Establishment of the industrial viability of the engineering concept for the production of vehicle body structures.

Procedure of roll forming: 

Concept of the “flexible stand”

Flexible roll formed profile prototypes

Project Science and Technological (S&T) objectives and approach

The objectives that need to be fulfilled in order to develop this new engineering and manufacturing concept and the S&T approach established for its achievement are:

• Development of an experimental platform for the production of non-constant section profiles by enhanced RF strategies (Flexible roll forming line).
• Integrated laser assisted techniques into the flexible roll forming line.
• Integration of non-continuous forming stages into continuous roll forming strategies.
• Adaptation of roll forming technology for the manufacturing of new materials like laminated sheets (steels, aluminium), laminated composites (multilayer sheets).
• Development of coils with ultraconductive materials to reduce the electric resistance in EMF.
• Development of nano reinforced resins to embed the coils for EMF.
• Development of coatings/film/laminates that increment the electric conductivity of the steel.
• Development of high resistant EMF dies.
• Development of an efficient EMF platform.
• Converting EMF suitable for steel by means of an efficient EMF platform and/or incrementing steel conductivity
• Development of laser cells for 3D laser forming processes and laser assisted roll forming.
• Development of an efficient LF platform using LZH laser forming installation.
• Development of an experimental platform joining the three emerging technologies.
• Development of numerical simulation strategies.

More information about the project on: www.proform-ip.org