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

通过其高科技战略，联邦政府的目标是越来越多地实现制造技术和机械、物流、工件和商品等子系统的数字化。这些现代化的发展往往伴随着定制材料的组合或替代，以及新的结构概念和功能元素的整合。因此，智能和/或轻质部件可以通过附加的信息和通信技术传感器来设计。该项目的目标是以科学为导向调查潜在的材料组合，并确定准确的工艺变量，以在双壁深冲容器的壁面和底部产生足够的接触和压力条件。这些容器的特点是具有感官特性的集成功能元件以及用于紧固系统和局部加强的功能元件。最后，应开发一种拉深双毛坯的方法，并使用部件底部两个毛坯之间的功能元件，如螺母、加强板和感官部件进行验证。这两个单毛坯的连接是通过拉深过程进行的，通过选择合适的板厚和两个毛坯的材料强度来实现壁面和底部的摩擦。随后，对单个毛坯进行先前或随后的激光焊接或部分结构粘接应该会增加双毛坯的连接强度。如果成形后毛坯的两壁之间不能达到足够的粘结强度和压缩比，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.