Influence of Stress States on Forming Hybrid Parts with Sheet Metal and Additively Manufactured Element

Abstract

Hybrid parts with additively manufactured elements (AME) combine the advantages of two or more manufacturing processes, e.g., forming and additive manufacturing (AM), and thus offer a solution to the increasing demands of industrial trends such as personalized mass production. Despite their advantageous properties, research in this field still lacks in clear classification and process interactions. Due to the strong influence of the AME on the formability of hybrid parts, the combination of laser-based powder bed fusion (PBF-LB) with subsequent sheet metal forming is examined in this paper. Therefore, cylindrical functional elements are built up on sheet metal and the resulting hybrid components are subsequently formed. Common forming processes such as bending, stretch forming and deep drawing are compared in regard to the different stress states. The results show a reduction in formability for hybrid components compared to conventional sheet metal materials. Reasons found are geometrical properties, gradients of mechanical properties and induced stresses. Consequently, requirements for the additive manufacturing process regarding a subsequent forming process are outlined. Namely, the gradient of mechanical properties should be smoothened, residual stresses kept low and the design of AMEs should avoid stress concentration.

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“…To process metals and their alloys, powder-based fusion (PBF) and directed energy deposition (DED) methods are being used. The PBF-based techniques such as selective laser sintering and direct metal laser sintering are focused to process the materials in powder form, whereas techniques under the DED process, namely wire arc additive manufacturing (WAAM) and electron beam additive manufacturing (EBAM), are dedicated to raw material in wire form (Liu and Shin, 2019; Hafenecker et al , 2021). With the wide coverage of manufacturing aspects, 3D printing becomes the emerging area of research and the choice of industries.…”