Stretch Forming Machine for Bumper Beam -

PBF Stretch Forming Machine for Bumper Beams is a specialized manufacturing tool designed for shaping and forming the structural components of automotive bumpers. PBF stretch bending machine utilizes a stretching process to shape metal sheets into the desired contours and profiles required for bumper beams.

The PBF Stretch Forming Machine‘s control system, often CNC-based, ensures precise and repeatable forming according to design specifications. It accommodates various sizes and materials used in bumper beam production, offering flexibility in manufacturing. The stretch forming process enhances the structural integrity and design precision of bumper beams, crucial components for vehicle safety.

Aluminum Bumper Beam Stretch Forming Process

Aluminum bumper beams are structural components in cars crafted from aluminum alloys. Vehicles employ aluminum bumper beams for several reasons, primarily to achieve a balance between strength and weight savings. The lightweight nature of aluminum aids in enhancing fuel efficiency and overall vehicle performance. The use of aluminum in bumper beams contributes to the reduction of the vehicle’s overall weight, supporting automakers’ efforts to meet fuel efficiency standards and improve handling.

Key features of aluminum bumper beams include their excellent strength-to-weight ratio, corrosion resistance, and malleability, allowing for versatile design options. The material’s ability to absorb and dissipate impact energy during collisions enhances passenger safety. Additionally, aluminum’s recyclability aligns with sustainability goals in the automotive industry.

Overall, aluminum bumper beams represent a strategic choice in vehicle design, offering a combination of structural integrity, weight reduction, and environmental sustainability. Their utilization aligns with the broader industry trend toward lightweight materials for improved efficiency and safety.

Challenges in Bending Aluminum Alloy Bumper Beams

Uncontrollable springback;
Deformation of the cross-section after bending;
Stability of curvature fit;
Uncertainty in where to start and difficulty in finding suitable theoretical support.

Innovation in the Production Process of Bumper Beams

Numerical Control Stretch Forming

Adaptation: Large-scale, diverse, multi-curved segments, angles ranging from 10º to 85º
Efficiency: 25-45 seconds per piece;
Qualification Rate: 99.9%;
Profile Deviation: 0.5-1mm (Key Reference Points: ±0.2mm);
Process: T4 aluminum profiles → Stretch Bending → Aging to T6 → CNC Machining
Operation: No need for skilled technical workers, automatic generation of bending trajectories;
Procedure: Import graphics for automatic programming and generation of production data;

Case Study

Material: 7T09 series aluminum alloy
Yield Strength: 350±30Mpa
Cross-sectional Area: 1330.78mm^2
Bending Material State: T4
Bending Forming Force: 65.5T

Image Description

A: Tightening blocks on both sides to ensure that the straight segment is not bent;
B: Middle tightening block to ensure proper filling of the core rod and prevent the straight segment from bending during the bending process;
C: Positioning hole;
D: Filling, ensuring no wrinkles after stretching and forming;
E: Must be filled before bending, or else it may collapse. The equipment comes with filling and extraction functions.

Process:

T4 aluminum profiles → Bending → Aging to T6 → CNC Machining

Length of straight segments at the ends: <80, groove depth 0.3, consistent clamping marks, no sliding teeth;
Bending radius: ±1mm, straightness: ±1mm;
Production cycle: 35-45s/piece;
Qualification rate: ≥99.9%; CPK: >=1.33.