Details
| Original language | English |
|---|---|
| Pages (from-to) | 569-581 |
| Number of pages | 13 |
| Journal | Production Engineering |
| Volume | 14 |
| Issue number | 5-6 |
| Early online date | 7 Nov 2020 |
| Publication status | Published - Dec 2020 |
Abstract
This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.
Keywords
- Bulk metal forming, Finite element method, Hybrid components, Intermetallic phases, Tailored forming, Virtual element method
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 14, No. 5-6, 12.2020, p. 569-581.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing
AU - Behrens, Bernd Arno
AU - Maier, Hans Jürgen
AU - Poll, Gerhard
AU - Wriggers, Peter
AU - Aldakheel, Fadi
AU - Klose, Christian
AU - Nürnberger, Florian
AU - Pape, Florian
AU - Böhm, Christoph
AU - Chugreeva, Anna
AU - Coors, Timm
AU - Duran, Deniz
AU - Thürer, Susanne E.
AU - Herbst, Sebastian
AU - Hwang, Jae Il
AU - Matthias, Tim
AU - Heimes, Norman
AU - Uhe, Johanna
N1 - Funding Information: The results presented were obtained in the subprojects A1, A2, B2, B3, C1, C3 and C4 of the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming”-252662854. The authors thank the Deutsche Forschungsgemeinschaft (German Research Foundation, DFG) for their financial support.
PY - 2020/12
Y1 - 2020/12
N2 - This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.
AB - This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.
KW - Bulk metal forming
KW - Finite element method
KW - Hybrid components
KW - Intermetallic phases
KW - Tailored forming
KW - Virtual element method
UR - http://www.scopus.com/inward/record.url?scp=85095584304&partnerID=8YFLogxK
U2 - 10.1007/s11740-020-00992-7
DO - 10.1007/s11740-020-00992-7
M3 - Article
AN - SCOPUS:85095584304
VL - 14
SP - 569
EP - 581
JO - Production Engineering
JF - Production Engineering
SN - 0944-6524
IS - 5-6
ER -