Process combination of combined deep drawing and cold forging

在第一个资助期内，已经证明，深冲和冷锻相结合的工艺可以用于生产由轻质芯和高强度钢壳组成的混合轴。第二个资助期的目标是调整工艺，以增加可能的部件范围，并提高复合材料伙伴之间的结合质量。穿孔圆片的使用被认为是连接扩孔和正向挤压的过程，以便能够涂覆任意轴区域。除此之外，多级深冲还用于生产在整个长度上覆盖高强度钢的轴。为了增加基本工艺及其变化中的所得结合强度，研究了反压力的应用以进一步扩大工艺窗口。研究了材料组合的变化以进一步增加轻量化潜力（e. G.镁作为芯材料）。镁及其合金由于具有六方晶格结构，很难形成。在这方面，将研究在多大程度上由周围高强度壳体产生的静水压力将有助于接头形成过程。最后，通过新材料组合的组合，如：G.使用铜作为钢壳以增加导电性。

In the first funding period, it was shown that the process of combined deep-drawing and cold forging can be used to produce hybrid shafts, consisting of a lightweight core and a high strength steel shell.The goals of the second funding period is the adaptation of the process in order to increase the possible component spectrum, as well as to increase the bond quality between the composite partners. The usage of perforated circular sheets is supposed to link the processes of hole expansion and forward extrusion, in order to enable coating of arbitrary shaft regions. In addition to this, multi-stage deep-drawing is used to produce shafts that are covered with a high strength steel over its complete length. In order to increase the resulting bond strengths in the basic process as well as its variations, the application of a counter-pressure is investigated in order to further enlarge the process window.A variation of the material combinations is investigated in order to further increase the lightweight potential (e. g. magnesium as a core material). Due to the hexagonal lattice structure, magnesium and its alloys are difficult to form. In this regard it will be investigated to what extent the hydrostatic pressure resulting from the surrounding high strength shell will help in the joint forming process. Lastly, new features are investigated by combination of new material combinations, e. g. the use of copper as a steel shell for increasing the electrical conductivity.