Forming and joining of sheet and bulk metal parts in a progressive die to produce a hybrid steel track control arm

Project title Forming and joining of sheet and bulk metal parts in a progressive die to produce a hybrid steel track control arm (Folgeverbundhybridschmieden)
Project duration 01.11.2017 – 31.10.2019
Press release

German small and medium-sized enterprises face constantly growing pressure to innovation in the field of automotive lightweight design. Especially, components produced by conventional die forging processes exhibit limited competitiveness on global markets. Reasons for this – among others – are the rising energy costs, expensive investment costs for the machinery and high amount of processing steps.

A potential solution for the stated drawbacks is provided by the technology of hybrid forging in a progressive die (HFPD). Hybrid forging facilitates the positive-fit connection of a sheet metal element with a bulk component using a significantly reduced amount of pressing force in comparison to conventional forging technologies. Reduced pressing forces enabled by the reduced degree of deformation lead to a decrease of the energy costs and the investment costs for the machinery. Additional benefit yields the fact that the hybrid forging will be realized within a progressive die. Therefore, it will be possible to integrate the processing steps prior and posterior to the hybrid forging within one single die. This will result in an increase of the production efficiency. Furthermore, the components manufactured by the HFPD technology exhibit higher strength compared to their equivalents made of pure sheet metal.

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Sponsor

The IGF project 19750 N of the Research Association for the Application of Steel (FOSTA) is funded via the German Federation of Industrial Research Associations (AiF) in the programme of Industrial Collective Research (IGF) by the Federal Ministry for Economic Affairs and Energy (BMWi) based on a decision of the German Bundestag.

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