Numerical investigations on the influence of the weld surface and die geometry on the resulting tensile stresses in the joining zone during an extrusion process

authored by: Bernd Arno Behrens, Deniz Duran, Johanna Uhe, Tim Matthias
Abstract: Bulk metal components are often used in areas which are subjected to very high loads. For most technical components, a distinction between structural and functional areas can be made. These areas usually have very different loading profiles, sometimes with contradictory requirements. Nevertheless, nowadays almost only monomaterials are used for the production of bulk metal components. With increasing requirements towards more and more efficient products with lower weight, compact design and extended functionality, these materials are reaching their material-specific limits. A significant increase of product quality and economic efficiency can be expected exclusively with locally adapted properties by combining different materials within one component. In this regard, the focus of this contribution is the production of a hybrid pinion shaft made of the material combination steel (37CrS4) and aluminium (AW6082). The tool concept for extrusion of the hybrid preform, the simulation-based design of the forming process as well as the material characterisation are presented. With the help of the FE-simulation, different serially arranged semi-finished component geometries were investigated in order to minimise the occurring tensile stresses in the component during the extrusion process to prevent failure during forming.
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/esaform21.919 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{ce3c95c1a64f491e8cfbb7d24efa2703,
title = "Numerical investigations on the influence of the weld surface and die geometry on the resulting tensile stresses in the joining zone during an extrusion process",
abstract = "Bulk metal components are often used in areas which are subjected to very high loads. For most technical components, a distinction between structural and functional areas can be made. These areas usually have very different loading profiles, sometimes with contradictory requirements. Nevertheless, nowadays almost only monomaterials are used for the production of bulk metal components. With increasing requirements towards more and more efficient products with lower weight, compact design and extended functionality, these materials are reaching their material-specific limits. A significant increase of product quality and economic efficiency can be expected exclusively with locally adapted properties by combining different materials within one component. In this regard, the focus of this contribution is the production of a hybrid pinion shaft made of the material combination steel (37CrS4) and aluminium (AW6082). The tool concept for extrusion of the hybrid preform, the simulation-based design of the forming process as well as the material characterisation are presented. With the help of the FE-simulation, different serially arranged semi-finished component geometries were investigated in order to minimise the occurring tensile stresses in the component during the extrusion process to prevent failure during forming.",
keywords = "Extrusion, Finite element method, Hybrid component, Steel-aluminium, Tailored forming",
author = "Behrens, {Bernd Arno} and Deniz Duran and Johanna Uhe and Tim Matthias",
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” in the subproject T02 – 252662854. 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/esaform21.919",
language = "English",
isbn = "9782870193020",
booktitle = "ESAFORM 2021 - 24th International Conference on Material Forming",
publisher = "ULi{\`e}ge Library",
}