- The IPH
Within the Collaborative Research Centre (CRC) 1153 “Tailored Forming “the manufacturing of hybrid bulk components is investigated. Therefore, a process chain consisting of joining, forming, milling and quality control has been established by multiple subprojects.Within subproject B1 of the CRC forming of hybrid parts by the incrementally forming cross-wedge rolling (CWR) process is investigated. The superior aim is to determine process limits and capabilities, when forming parts consisting of different materials joined by varying technologies.
In this paper, the investigation of cross-wedge rolling of serially arranged hybrid parts made of steel and aluminum is described. The focus of the research presented in this publication is the displacement of the joining zone of hybrid parts due to the cross-wedge rolling process. Therefore, finite element simulations have been developed, that allow the investigations of hybrid solid components. After simulation of various variations of the cross-wedge rolling process, i.e. differently shaped tools and forming velocities, experimental trials were carried out with identical parameter sets. A comparison of simulation and experiment, showed that the simulation model is capable of describing the cross-wedge rolling process of hybrid parts. The standard deviation of the displacement of the joining zone between simulation and experimental trials is 8.8% with regard to all investigated cases.
tailored forming, cross-wedge rolling, material forming, aluminum, steel
Multi-stage process chains are often used for the efficient production of complex geometries. These consist of a homogeneous heating, one or more preform stages and the final forging step. Via inhomogeneously heated blanks, the process chains are to be simplified or shortened. This is to be achieved by setting several, clearly defined temperature fields in which different yield stresses are present. These can influence the material flow, leading to an easier production of complex parts.
inhomogeneous heating, bulk forming, preforming processes