EUREKA SMART TOPAS2

Important results from the project

The project aims to develop an innovative European manufacturing chain for aircraft or trains optimized in terms of materials, design and a combination of advanced manufacturing techniques. Successful development in this area opens up completely new production alternatives with potential major gains in material utilization and production speed. ORTIC has developed the 3D roll forming process for new products within Aerospace as part of the manufacturing chain. In the longer term, ORTIC can supply a production line adapted for this purpose.

Expected long term effects

ORTIC has manufactured and delivered a prototype that has been accepted by the international consortium for further analysis. Several different combinations of advanced alloys, sheet thicknesses and heat treatments have been tested in the project. Further work is required to get closer to a commercial product regarding the end customers quality requirements. Process improvements have been identified for possible further work. ORTIC´s objective in the project to deliver a prototype can be considered fulfilled, however not yet the long-term goal of delivering a machine line.

Approach and implementation

The following steps have been carried out by ORTIC: Optimization of cutting file, tool design, FEA simulations, tool optimization, development of control data for 3D roll forming, coordination of heat treatment tests, 3D roll forming prototype production, process design and development of bending process in a 3D prototype machine, process optimizations to improve quality of prototypes, manufacturing of a gauge to verify the geometries of the prototypes, reporting of results, identification of improvements to achieve closer to quality requirements for commercial products.