Title:
Efficient small-batch production of a sheet metal door frame using RoRoFo
Effiziente Kleinserienfertigung eines Türspantes in Blechbauweise mittels RoRoFo
Authors:
T. Abdolmohammadi, V. Richter-Trummer, M. Werner, K. Richter, A. Ahrens, W. Schulze
Abstract:
The production of aluminum door frames is typically carried out by milling from a large block, resulting in chip volumes exceeding 90%. This work presents a sheet metal door frame design that is significantly more material-efficient, with a material utilization rate of over 90% and thus less than 10% waste. To ensure efficient production even with small batch sizes, a robot-based roll forming process (RoRoFo) was developed and implemented. In this process, an end effector with a double roller set, guided by an articulated robot arm, travels along an FE-optimized bending curve and incrementally forms the sheet metal. To maximize production efficiency and, in particular, to ensure the form and positional tolerances of sheet metal components, an approach is further described that integrates straightening processes into the final forming increments.
Event:
Deutscher Luft- und Raumfahrtkongress 2025, Augsburg
Location, Year:
Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V., Bonn, 2026
Format:
21,0 x 29,7 cm, 5 Pages
Descriptors:
EN: Roll forming, forming technology, industrial robots, incremental bending
Citation:
Abdolmohammadi, T.; Richter-Trummer, V.; et al. (2026): Effiziente Kleinserienfertigung eines Türspantes in Blechbauweise mittels RoRoFo. DGLR Published Conference Papers. Volume 4. (2026). ISSN: 2941-3451. Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V.. (Text). https://doi.org/10.25967/650131. urn:nbn:de:101:1-2601161321416.849710960182.
Publishing Date:
16.01.2026