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Component Optimization by Forging of Composite Aluminum Extrusions

通过复合铝型材锻造进行成分优化

基本信息

批准号：
138690682
负责人：
Professor Dr.-Ing. Bernd-Arno Behrens
金额：
--
依托单位：
Institut für Umformtechnik und Leichtbau (IUL)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2009
资助国家：
德国
起止时间：
2008-12-31 至 2016-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/138690682?language=en
关键词：
Component Optimization Forging Composite Aluminum

项目摘要

The benefit of multi-material components is characterized by the material-specific advantages of the used mono materials. The components are specifically adapted to the current requirement profiles. The object of this cooperation project is to study the process chain of compound extrusion and subsequent forging for the production of continuously steel-reinforced aluminum components.The manufacturing of partially and continuously reinforced components by combining hybrid extrusion and forging was investigated and the interactions between the processes were studied successfully. In the field of extrusion, a stable process control for rotationally symmetrical, partial composite extrusion could be realized and a pre-calculation of the reinforcing element position was achieved. It could be shown that it is possible to reinforce non-rotationally symmetrical profiles. Furthermore, the feasibility of the process combination of partial and continuous composite extrusion was demonstrated. For forging of partially and continuously reinforced raw parts, the change in position of the reinforcing elements during the material flow in the semi-finished aluminum parts was optimized on the basis of FEM simulations and experiments. In the following the influences on the joining zone quality were identified and qualified.Based on the results described, the possible product range shall be defined and extended in the second application phase by increasing the degree of complexity of the distribution of the reinforcing elements. From the superior target of adjusting a locally adapted distribution of the reinforcing elements in the composite part the following aspects are derived to be considered:- Hot extrusion of locally reinforced semi-finished products with non axially-symmetric cross section- Embedding of non-rotationally symmetric reinforcing elements- Manufacturing of profiles with excentric position of the reinforcing elements- Process design of the combination of continuous and discontinuous composite extrusion In the area of forging, the following issues will be addressed:- Analysis and control of the material flow in forging- Design of the geometry of the forging slug- Inhomogeneous preheating of the reinforced semi-finished aluminum parts for controlling of the formability the reinforcing elementsImportant milestones for both processes are the isolation and subsequent combination of corresponding process windows that consider the shape and the position of the reinforcing elements in the component. This also includes the characterization of the bonding zone and the component properties

多材料组件的优势在于所用单一材料的材料特定优势。这些组件专门适应当前的要求。该合作项目的目标是研究连续钢增强铝合金构件的复合挤压和后续锻造工艺链，研究了复合挤压和锻造相结合的部分和连续增强构件的制造，并成功地研究了工艺之间的相互作用。在挤压领域，实现了旋转对称局部复合挤压过程的稳定控制，并实现了增强元件位置的预测。可以证明，可以加强非旋转对称的轮廓。论证了部分挤压与连续挤压工艺组合的可行性。对于部分和连续强化的原始零件的锻造，在有限元模拟和实验的基础上，优化了在半成品铝零件中的材料流动期间强化元件的位置的变化。在下文中，对连接区域质量的影响进行了识别和鉴定。根据所述结果，应在第二应用阶段通过增加增强元件分布的复杂程度来定义和扩展可能的产品范围。从调节增强元件在复合部件中的局部适应性分布的上级目标出发，导出要考虑的以下方面：-具有非轴对称横截面的局部增强半成品的热挤压-非旋转对称增强元件的嵌入-具有增强元件偏心位置的型材的制造-连续和不连续复合挤压的组合的工艺设计在锻造领域，将解决以下问题：- 锻造中材料流动的分析和控制-锻坯几何形状的设计-强化半成品的不均匀预热用于控制可成形性的成品铝件和增强元件这两个过程的重要里程碑是隔离和随后的相应工艺窗口的组合考虑了部件中的增强元件的形状和位置。这还包括对粘合区和部件特性的表征