TY - GEN

T1 - Numerical evaluation of forging process designs of a hybrid co-extruded demonstrator consisting of steel and aluminium.

AU - Behrens, Bernd Arno

AU - Wester, Hendrik

AU - Petersen, Tom

AU - Uhe, Johanna

AU - Büdenbender, Christoph

AU - Peddinghaus, Julius

AU - Chugreeva, Anna

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” (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.

PY - 2021/4/14

Y1 - 2021/4/14

N2 - 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.

AB - 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.

KW - Die stress analysis

KW - Finite element modelling

KW - Forging

KW - Hybrid components

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85119321277&partnerID=8YFLogxK

U2 - 10.25518/esaform21.954

DO - 10.25518/esaform21.954

M3 - Conference contribution

AN - SCOPUS:85119321277

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 -