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

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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.