Introduction to tailored forming

Abstract

In recent years, the requirements for technical components have been increasing steadily. This development is intensified by the desire for products with lower weight, smaller size and extended functionality, but at the same time higher resistance against specific loads. Mono-material components manufactured according to established processes reach their limits regarding conflicting requirements. It is, for example, hardly possible to combine excellent mechanical properties with lightweight construction using mono-materials. Thus, a significant increase in production quality, lightweight design, functionality and efficiency can only be reached by combining different materials in one component. The superior aim of the Collaborative Research Centre (CRC) 1153 is to develop novel process chains for the production of hybrid solid components. In contrast to existing process chains in bulk metal forming, in which the joining process takes place during forming or at the end of the process chain, the CRC 1153 uses tailored semi-finished workpieces which are joined before the forming process. This results in a geometric and thermomechanical influence on the joining zone during the forming process which cannot be created by conventional joining techniques. The present work gives an overview of the CRC and the Tailored Forming approach including the applied joining, forming and finishing processes as well as a short summary of the accompanying design and evaluation methods.

Numerical Process Analysis of Forming Semi-Finished Hybrid Parts

“…Thus, the stresses occurring in the material during forming can be modified. In particular, critical tensile stresses in the area of the joining zone can be reduced in this way [4].…”

“…In this context, Tailored Forming is an innovative method for the production of hybrid components. In this process, pre-joined hybrid semi-finished parts are used, which offers the possibility of using simple semifinished part geometries and modifying the joining zone thermomechanical with regard to its geometry during the process [4]. Furthermore, different well-established joining processes like laser beam welding, laser, plasma powder welding or rotary friction welding can be applied depending on the used materials and application.…”

Data quality assurance in the research process using the example of tensile tests

“…Innerhalb des Sonderforschungsbereichs (SFB) 1153 wird die Prozesskette zur Herstellung hybrider Hochleistungsbauteile durch Tailored Forming erforscht, um ressourceneffizienten Leichtbau mittels lokal angepasster Eigenschaften von Massivbauteilen umzusetzen [11]. So bilden die anfallenden Forschungsdaten und zugehörigen Prozessbeschreibungen die Grundlage für die relevante Prozesskettenentwicklung und im Falle der Zugversuche für die Entwicklung von Materialmodellen der hybriden Bauteile.…”

Modelling failure of joining zones during forming of hybrid parts

“…They found that the precipitation hardened state of aluminium alloys are more suited for processing than the soft annealed state if the intention is to obtain a sound bonding behaviour with steel. An innovative manufacturing route for the production of hybrid components named Tailored Forming was developed using hybrid pre-joined semifinished [4]. The material combination of steel and aluminium has great potential for industrial application in hybrid components.…”