Lightweight design using high-strength aluminum alloys has gained in importance due to the continuing need for weight reduction and increasing crash safety requirements in the automotive industry. There are various manufacturing processes available for processing high-strength aluminum alloys. This work aims to compare the production of high-strength aluminum parts by roll forming and press forming based on the example of an AA7075 hat profile. Roll forming represents a continuous manufacturing process, while press hardening is a discontinuous process.
Three different process routes (T6, W-Temper, O) for roll forming as well as for press forming (T6, hot forming-quenching, O) are in focus of the investigation. Fundamental differences of the forming processes and the tempering condition are observed. The temperature-supported process routes improve the poor cold formability of AA7075 alloy and thus enhance the process window. A description of the process design in terms of tool design and numerical simulation is given separately for both processes. The influence of the different forming strategies on the mechanical properties of the manufactured parts is investigated. In addition, production rate, energy efficiency and economic aspects of roll forming and press forming are compared.