Perforated 3D components
DEEP DRAWING AT SOLVARO
Forming at Solvaro
Deep drawing to perfection
Deep drawing perforated metal components is one of the most demanding forming tasks – in addition to specialised deep drawing tools, it requires above all experience, practical knowledge and a sure instinct. However, those who accept the “deep drawing challenge” in the production of perforated sheets will be rewarded with optimum results: no other forming process offers such far-reaching design and optimisation possibilities to combine the versatile requirements of function, design, weight and air permeability.
Deep drawing tools are expensive to purchase – but can significantly reduce the unit costs in series production and at the same time meet all specifications. The decisive factor is the maturity of the deep drawing tool for series production: to ensure this, we work closely with our customers right from the early planning phase. Solvaro’s specialists provide you with the concentrated deep-drawing experience from highly complex projects. Above all, these aspects are decisive for the success of the project:
Deep drawing depends on expertise and know-how: 200,000 deep-drawn parts per year speak for the high quality we achieve with this technique.
Csaba Genzler, Head of Key AccountThe selection of the raw material
Even the selection of the raw material can have a decisive influence on the quality of the perforated component. In deep drawing, for example, steel grades such as DC04-DC07, which have different deep drawing qualities, can be used as basic materials. The choice of material has an influence on the flow behaviour, among other things – and is thus also decisive for the occurrence of rejects.
A more expensive base material can lead to cost advantages in production thanks to its more precise flow behaviour. Together with our customers, we therefore decide in the first step which raw material is best suited for the individual requirements.
Perforation quality
Perforated sheet metal behaves completely differently during deep drawing than solid material. The thin webs of perforated metal components react extremely sensitively to minimal changes. Therefore, practical experience and a sure instinct are essential.
At Solvaro, we work with our customers to find the ideal parameters for perforation. Important component requirements such as design, stability, corrosion protection and filter effect depend to a large extent on hole pitch, hole width and web width. In addition, the choice of the right hole geometry – hexagonal or round perforation – is decisive for the air passage.
Success through teamwork: Together with our customers, we have already developed around 500 different deep-drawn articles.
Bence Osvald, Team Leader Application TechnologyForming at Solvaro
APPLICATION AREAS
Tool competence
The development of a deep drawing tool is time-consuming, complex and expensive. It is therefore all the more important to work towards a high level of maturity for series production right from the start and to avoid expensive changes during development.
At Solvaro, we succeed in this through experience, know-how and a wealth of ideas. For example, at the customer’s request, we use high-quality hammer-formed models as prototypes so that initial tests on air passage and installation can be carried out. The moulds can be cheaply milled from steel or aluminium, then a usually soft-annealed perforated sheet is hammerd into shape on a negative mould. Thanks to expert techniques, we manage to create a prototype that is very close to the final product.
The advantage is that the customer gains valuable insight into the feasibility of the vehicle, without having to use cost-intensive deep drawing tools. This allows us to easily respond to design changes and develop a tool with high production maturity.
Setting of drawing parameters
When it comes to deep drawing perforated metal components, it’s not only computer-aided processes and sophisticated production methods that are decisive – the human factor is also crucial. The flow behaviour of perforated sheets is not comparable with solid material. It is only through intuition and practical experience that it is possible to control the forces in deep drawing and avoid cracks and deformations.
Based on many years of experience, we are able to precisely define the correct parameters for deep drawing. These include in particular the drawing radius and the drawing speed, which we adapt individually to the customer’s requirements for the perforated sheet in the course of extensive tests.
At Solvaro, we include the knowledge of the correct drawing parameters already in the planning phase. This enables us to ensure the required quality standards at an early stage and to reduce costs.
Busy almost around the clock: Last year, our deep drawing presses were in operation for over 5,000 hours.
Dániel Kövecses, Plant Manager
