Hybrid-Forging: Combined Forming and Joining of Sheet and Bulk Metal

混合锻造：板材和块状金属的联合成型和连接

• 批准号: 167240961
• 负责人: Dr.-Ing. Malte Stonis
• 金额: --
• 依托单位: Institut für Umformtechnik und Umformmaschinen (IFUM)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2010
• 资助国家: 德国
• 起止时间: 2009-12-31 至 2017-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/167240961?language=en
• 关键词: Hybrid; Forging; Combined; Forming; Joining

Lightweight structural components are often designed for the needs of assembly and function. They often have bulk- and sheet-elements. Nowadays, these elements are separately manufactured and subsequently joined in additional process steps, for example by welding or a screw connection.In the first funding period a simulative and experimental study of the basics of hybrid forging was investigated. Hybrid forging is the forging of bulk parts, the forming of sheet metal components and the joining of these parts in a single step. Material bonding mechanisms and positive locking have been evaluated in three model experiments (HS1 to HS3) using FE-simulations and practical experiments. The influence of the parameters deformation, temperatures of sheet metal and bulk elements, and the friction was investigated on the quality of the joint between solid and sheet metal element and the sheet thickness. In model experiment HS1 and HS2 partially a material bonding was achieved. In model experiment HS3 a positive locking was achieved. However, the sheets bulged partially, were bent unintentionally and were reduced in their thickness.The aim of the second period of this research project is the development of the hybrid forging based on the insights developed in the first period. The deformation of the sheet (bulging, bending, and sheet thickness reduction) shall be reduced and the quality of the joining shall be increased. The deformation is to be reduced by sheet materials with a higher strength and greater thickness, and by the use of blank holders. The joining quality is enhanced by a geometrically forced relative motion of the bulk in relation to the sheet metal element. An exemplary hybrid forging part with variable elements made of common sheet metal and forging materials as well as the deformation process will be developed. Furthermore, this example part should illustrate the different manufacturing operations, forming of sheet metal and bulk elements and joining (positive locking and material bonding) of the elements and allow a study of the interaction of forming and joining operations. Furthermore, forming tools are designed for experimental tests and metallurgical and mechanical properties of the hybrid parts are investigated, especially the joining areas.With the insight gained in this research the possibilities of designing structural components are extended that lightly loaded regions of a component can be substituted by sheet metal elements or elements can partially be reinforced by bulk elements. Due to the simultaneous bulk and sheet metal forming including joining the process chain is shortened compared to conventional process chains.

轻量化结构构件往往是为满足装配和功能的需要而设计的。它们通常有块状元素和板状元素。现在，这些零件是分开制造的，然后通过额外的工艺步骤连接起来，例如通过焊接或螺丝连接。在第一个资助期，我们对混合锻造的基础进行了模拟和实验研究。混合锻造是对整体零件的锻造、板料零件的成形以及这些零件的一次连接。在三个模型实验(HS1到HS3)中，利用有限元模拟和实际实验对材料结合机制和正锁定进行了评估。研究了变形参数、板材和体件温度、摩擦力等因素对实体与板材连接质量和板材厚度的影响。在模型实验中，HS1和HS2部分实现了材料粘结。在HS3模型试验中，实现了正锁定。本课题第二阶段的研究目标是在第一阶段研究成果的基础上，开发复合锻造技术。应减少板材的变形(胀形、弯曲和板厚减薄)，并提高连接质量。通过使用强度更高、厚度更大的板材以及使用压边机来减少变形。连接质量通过块体相对于金属板材的几何力相对运动而得到提高。将开发一种由普通板材和锻件材料制成的可变单元混合锻件及其变形工艺的示范性产品。此外，此示例部分应说明不同的制造操作、板材和块状零件的成形以及零件的连接(正锁定和材料粘合)，并允许研究成形和连接操作的相互作用。此外，还设计了成形工具进行实验，并对混杂零件的冶金性能和力学性能进行了研究，特别是连接区。通过本研究的认识，扩大了结构构件设计的可能性，即可以用板材来代替构件的轻载区域，或者可以用整体构件来部分增强构件。由于同时进行块成形和板料成形，因此与传统工艺链相比，包括加入工艺链在内的工艺链缩短了。

项目成果

Simulation study on the influence of process parameters on the hybrid forging quality of a control arm

工艺参数对控制臂混合锻造质量影响的仿真研究

• DOI: 10.1109/ieem.2016.7797924
• 发表时间: 2016
• 期刊: 2016 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM)
• 作者: Jagodzinski;Stonis;Behrens
• 通讯作者: Behrens