TY - GEN

T1 - 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

AU - Behrens, Bernd Arno

AU - Duran, Deniz

AU - Uhe, Johanna

AU - Matthias, Tim

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 T02 – 252662854. 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 - 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.

AB - 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.

KW - Extrusion

KW - Finite element method

KW - Hybrid component

KW - Steel-aluminium

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85118893420&partnerID=8YFLogxK

U2 - 10.25518/esaform21.919

DO - 10.25518/esaform21.919

M3 - Conference contribution

AN - SCOPUS:85118893420

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 -