Abstract
Multi-material solutions offer benefits, as they, in contrary to conventional monolithic parts, are customised hybrid components with properties that optimally fit the application locally. Adapted components offer the possibility to use high strength material in areas where external loads require it and substitute them by lightweight material in the other areas. The presented study describes the manufacturing of a hybrid shaft along the process chain Tailored Forming, which uses serial pre-joined semi-finished products in the forming stage. Subject of this study is the numerical modelling of the heating process by induction heating of a hybrid semi-finished product and the resulting material distribution after the impact extrusion process. For this endeavour, a numerical model of an inhomogeneous induction heating process was developed. The main challenge is to determine the boundary conditions such as current intensity acting in the induction coil and the electromagnetic properties of the used material. The current intensity was measured by a Rogowski coil during experimental heating tests. The relative magnetic permeability was modelled as a function of temperature using the method of Zedler. The results show the importance of using a relative magnetic permeability as a function of temperature to guarantee a high quality of the numerical model. Subsequently, the model was applied to the heating of the hybrid semi-finished product consisting of a steel and aluminium alloy. By using inductive heating and thus a resulting inhomogeneous temperature field, good agreement of the material distribution between experiment and simulation could be achieved after the forming process.
Highlights
In order to achieve the new emission limits negotiated by the European Union in 2020 [1], the automotive industry will continue to focus on lightweight constructions to meet the limit values
The resulting temperature-time-diagrams of the experimental tests were compared with the numerical results and show a very good agreement when using the relative magnetic permeability generated by the Zedler
An investigation of induction heating and subsequent impact extrusion using a serially arranged hybrid semifinished product consisting of steel 1.7147 and aluminium 3.2315 was carried out
Summary
In order to achieve the new emission limits negotiated by the European Union in 2020 [1], the automotive industry will continue to focus on lightweight constructions to meet the limit values. Novel full autonomic vehicles play a central role in the mobility of the future, there more sensor systems will increase the weight of the vehicle. Both challenges influence future designs and change the overall structure of vehicles and their weight. The manufacturing of hybrid components by bulk metal forming represents a promising method to produce near-net-shape functional components with complex geometries and outstanding mechanical properties within just a few processing steps [2]. An innovative manufacturing route for the production of hybrid components is investigated within the Collaborative Research Centre (CRC) 1153 Tailored Forming at the Leibniz University of Hanover. Further advantages are the design and realisation of complex load-adjusted joining zone shapes and a process integrated thermo-mechanical treatment of the joining zone
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