Integration of functional elements in sheet metal components through deep-drawn double blanks

联邦政府的高科技战略旨在提高制造技术和机器、物流、工件和商品等子系统的数字化程度。这些现代发展往往伴随着定制材料的组合或替代，结合新的结构概念和功能元素的整合。因此，智能和/或轻量化的部件可以设计为带有额外的信息和通信技术传感器。该项目的目标是对潜在的材料组合进行科学研究，并确定精确的工艺参数，以在双壁深冲容器的壁和底部产生足够的接触和压力条件。这些容器的特征在于具有感官特性的集成功能元件以及用于紧固系统和用于局部硬化的功能元件。最后，应开发并验证双坯件深冲的方法，在组件底部的两个坯件之间使用功能元件，如螺母、加强板和传感组件。这两个单个坯料的连接通过深冲压工艺来执行，其中通过选择两个坯料的合适的片材厚度和材料强度来实现壁部和底部处的摩擦。随后，单个坯件的先前或随后的激光焊接或部分结构结合应增加双坯件的连接强度。如果在成形之后不能在坯件的两个壁之间实现足够水平的结合强度和压缩比，则引入的元件将完全失去它们的功能。

With its high-tech strategy, the federal government is aiming for an increasing digitalization of manufacturing technologies and the subsystems such as machines, logistics, workpieces, and commodities. These modern developments are often accompanied by a combination or substitution of customized materials in combination with new structural concepts and the integration of functional elements. Therefore, intelligent and/or lightweight components can be designed with additional sensors of the information and communication technology.The objective of the project is the scientifically oriented investigation of potential material combinations and the determination of accurate process variables to generate sufficient contact and pressure conditions in the wall and at the bottom of double-walled, deep-drawn containers. These containers are characterized by integrated functional elements with sensory properties as well as functional elements for fastening systems and for local stiffening. Finally, a method for deep drawing of double blanks shall be developed and validated using functional elements such as nuts, stiffening plates, and sensory components between the two blanks at the bottom of the components. The joining of these two single blanks is performed through the deep drawing process, in which the friction in the wall and at the bottom is achieved by choosing a suitable sheet thickness and material strength of both blanks. Later on, a previous or subsequent laser welding or partial structural bonding of individual blanks should increase the joining strength of the double blanks. If no sufficient levels of bonding strength and compression ratios between the two walls of the blanks can be achieved after forming, the introduced elements will entirely lose their function.