Numerical evaluation of forging process designs of a hybrid co-extruded demonstrator consisting of steel and aluminium.

authored by: Bernd Arno Behrens, Hendrik Wester, Tom Petersen, Johanna Uhe, Christoph Büdenbender, Julius Peddinghaus, Anna Chugreeva
Abstract: Multi-material solutions represent a promising approach for the production of load-optimised parts. The combination of material-specific advantages of different materials in a single component allows the fulfilment of conflicting requirements e.g. high performance and low weight. Fabrication of hybrid components is challenging due to the dissimilar properties of the individual materials and requires the development of suitable manufacturing technologies. The present paper deals with the simulation-based design of a forming process for the production of a suspension control arm consisting of steel and aluminium. With the focus on material flow, two forming concepts, open-die and closed-die forging, were investigated, in order to ensure the required material distribution similar to the final part. In addition, a tool analysis was carried out to avoid thermo-mechanical overload of the tool system. It was found that the required material distribution can be achieved with both forming concepts. However, a closed-die forging concept is not suitable because of the high stresses in the forging dies exceed the tool steel's strength.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Publication date: 14.04.2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all)
Electronic version(s): https://doi.org/10.25518/esaform21.954 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{522ab66395d240bb9991d3148e1a4848,
title = "Numerical evaluation of forging process designs of a hybrid co-extruded demonstrator consisting of steel and aluminium.",
abstract = "Multi-material solutions represent a promising approach for the production of load-optimised parts. The combination of material-specific advantages of different materials in a single component allows the fulfilment of conflicting requirements e.g. high performance and low weight. Fabrication of hybrid components is challenging due to the dissimilar properties of the individual materials and requires the development of suitable manufacturing technologies. The present paper deals with the simulation-based design of a forming process for the production of a suspension control arm consisting of steel and aluminium. With the focus on material flow, two forming concepts, open-die and closed-die forging, were investigated, in order to ensure the required material distribution similar to the final part. In addition, a tool analysis was carried out to avoid thermo-mechanical overload of the tool system. It was found that the required material distribution can be achieved with both forming concepts. However, a closed-die forging concept is not suitable because of the high stresses in the forging dies exceed the tool steel's strength.",
keywords = "Die stress analysis, Finite element modelling, Forging, Hybrid components, Tailored forming",
author = "Behrens, {Bernd Arno} and Hendrik Wester and Tom Petersen and Johanna Uhe and Christoph B{\"u}denbender and Julius Peddinghaus and Anna Chugreeva",
note = "Funding Information: The results presented in this paper were obtained within the Collaborative Research Centre 1153 “Process chain to produce hybrid high-performance components by Tailored Forming” (project number: 252662854, subprojects B2 and C1). The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project. ; 24th International ESAFORM Conference on Material Forming, ESAFORM 2021 ; Conference date: 14-04-2021 Through 16-04-2021",
year = "2021",
month = apr,
day = "14",
doi = "10.25518/esaform21.954",
language = "English",
isbn = "9782870193020",
booktitle = "ESAFORM 2021 - 24th International Conference on Material Forming",
publisher = "ULi{\`e}ge Library",
}