Composite Cold Forging of Cold Forged Semi-Finished Parts

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The aim of the project is the Investigation of the production and further processing of composite compoents by cold extrusion. Cold forging is used for the production of the raw parts, which are then further processed by the composite extrusion. The main focus of the overall project is on the characterization and adjustment of the composite properties as well as on the increase of the lightweight potential and the functional integration by combining materials with different physical properties. The determination of the adjustable wall thicknesses is part of work programm. The mechanical properties resulting from the forming history of the process are used for the production of new lightweight components.In the first phase of the project, the process chain was analyzed analytically, numerically and experimentally. These were mainly steel-aluminium composite shafts as a replacement for solid shafts made of steel. The bond strength was analyzed under the aspects of force and form fit as well as metallurgical bond. Hybrid shafts can be produced reliably with the composite extrusion in various geometries. In the second phase of the project, the composite extrusion is further investigated in terms of lightweight construction as well as functionality. The focus of lightweight construction is on a further weight reduction without reducing the properties, which are relevant for the final component, e.g. torsional stiffness. This should be achieved by the use of alternative core materials, such as plastic, or the production of hollow shafts by means of lost cores.