Laser-Assisted Robotic Roller Forming of Ultrahigh-Strength Steel QP1180 with High Precision

Area of Science:

• Materials Science
• Manufacturing Engineering

Background:

• Forming low-ductility materials like ultrahigh-strength steel presents significant challenges.
• Traditional forming methods often struggle with achieving desired shapes and precision for these materials.

Purpose of the Study:

• To investigate the application of laser-assisted robotic roller forming (LRRF) for bending ultrahigh-strength steel (1180 MPa).
• To analyze the impact of laser power density on bending forces, springback, and final part geometry.

Main Methods:

• Utilized laser-assisted robotic roller forming (LRRF) on ultrahigh-strength steel sheets.
• Varied laser power density to observe its effects on the forming process.
• Measured bending forces, springback angles, and bending radius.

Main Results:

• LRRF reduced bending forces by up to 43%.
• Achieved a compact profile with minimal springback (<1°) and a radius-to-thickness ratio of ~1.2 at 10 J/mm².
• Decreased forming forces with laser power density >7.5 J/mm² due to elevated temperatures and reduced material strength.

Conclusions:

• LRRF is a viable solution for overcoming the formability limitations of low-ductility materials.
• Optimized laser power density (10 J/mm²) enables high-precision forming of ultrahigh-strength steel.
• The process facilitates reduced springback and sharp bending radii through controlled heating and deformation.