TY - GEN

T1 - Modelling of an induction heating process and resulting material distribution of a hybrid semi-finished product after impact extrusion

AU - Behrens, Bernd Arno

AU - Wester, Hendrik

AU - Schäfer, Stefan

AU - Büdenbender, Christoph

N1 - 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 C1. The authors would like to thank the German Research Foundation (German Research Foundation, DFG, 252662854) for the financial and organisational support of this project.

PY - 2021/4/14

Y1 - 2021/4/14

N2 - Multi-material solutions offer benefits, as they, in contrary to conventional monolithic parts, are customised hybrid components with properties that optimally fit the application locally. Adapted components offer the possibility to use high strength material in areas where external loads require it and substitute them by lightweight material in the other areas. The presented study describes the manufacturing of a hybrid shaft along the process chain Tailored Forming, which uses serial pre-joined semi-finished products in the forming stage. Subject of this study is the numerical modelling of the heating process by induction heating of a hybrid semi-finished product and the resulting material distribution after the impact extrusion process. For this endeavour, a numerical model of an inhomogeneous induction heating process was developed. The main challenge is to determine the boundary conditions such as current intensity acting in the induction coil and the electromagnetic properties of the used material. The current intensity was measured by a Rogowski coil during experimental heating tests. The relative magnetic permeability was modelled as a function of temperature using the method of Zedler. The results show the importance of using a relative magnetic permeability as a function of temperature to guarantee a high quality of the numerical model. Subsequently, the model was applied to the heating of the hybrid semi-finished product consisting of a steel and aluminium alloy. By using inductive heating and thus a resulting inhomogeneous temperature field, good agreement of the material distribution between experiment and simulation could be achieved after the forming process.

AB - Multi-material solutions offer benefits, as they, in contrary to conventional monolithic parts, are customised hybrid components with properties that optimally fit the application locally. Adapted components offer the possibility to use high strength material in areas where external loads require it and substitute them by lightweight material in the other areas. The presented study describes the manufacturing of a hybrid shaft along the process chain Tailored Forming, which uses serial pre-joined semi-finished products in the forming stage. Subject of this study is the numerical modelling of the heating process by induction heating of a hybrid semi-finished product and the resulting material distribution after the impact extrusion process. For this endeavour, a numerical model of an inhomogeneous induction heating process was developed. The main challenge is to determine the boundary conditions such as current intensity acting in the induction coil and the electromagnetic properties of the used material. The current intensity was measured by a Rogowski coil during experimental heating tests. The relative magnetic permeability was modelled as a function of temperature using the method of Zedler. The results show the importance of using a relative magnetic permeability as a function of temperature to guarantee a high quality of the numerical model. Subsequently, the model was applied to the heating of the hybrid semi-finished product consisting of a steel and aluminium alloy. By using inductive heating and thus a resulting inhomogeneous temperature field, good agreement of the material distribution between experiment and simulation could be achieved after the forming process.

KW - Finite element method

KW - Induction heating

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85119337044&partnerID=8YFLogxK

U2 - 10.25518/esaform21.574

DO - 10.25518/esaform21.574

M3 - Conference contribution

AN - SCOPUS:85119337044

SN - 9782870193020

BT - ESAFORM 2021 - 24th International Conference on Material Forming

T2 - 24th International ESAFORM Conference on Material Forming, ESAFORM 2021

Y2 - 14 April 2021 through 16 April 2021

ER -