Abstract
Multi-material solutions represent a promising approach for the production of load-optimised parts. The combination of material-specific advantages of different materials in a single component allows the fulfilment of conflicting requirements e.g. high performance and low weight. Fabrication of hybrid components is challenging due to the dissimilar properties of the individual materials and requires the development of suitable manufacturing technologies. The present paper deals with the simulation-based design of a forming process for the production of a suspension control arm consisting of steel and aluminium. With the focus on material flow, two forming concepts, open-die and closed-die forging, were investigated, in order to ensure the required material distribution similar to the final part. In addition, a tool analysis was carried out to avoid thermo-mechanical overload of the tool system. It was found that the required material distribution can be achieved with both forming concepts. However, a closed-die forging concept is not suitable because of the high stresses in the forging dies exceed the tool steel’s strength.
Highlights
With the worldwide effort to reduce energy consumption and carbon dioxide (CO2) emissions, the lightweight construction trend, relevant for the transportation industry, is gaining in importance [1]
Multi-material design offers a promising approach for the production of application-optimised components, where the material arrangement can be tailored in accordance with the local requirements and the operational conditions [4]
Inspired by a suspension control arm, the present paper introduces two possible forming concepts for the production of a linear symmetric system demonstrator consisting of a steel reinforcement element and an aluminium matrix within the Tailored Forming process chain (Fig. 1)
Summary
With the worldwide effort to reduce energy consumption and carbon dioxide (CO2) emissions, the lightweight construction trend, relevant for the transportation industry, is gaining in importance [1]. To fulfil the conflicting requirements such as high strength, low mass, compact design and improved stiffness, the development of advanced manufacturing technologies is of great importance for both research and industry. In this context, multi-material design offers a promising approach for the production of application-optimised components, where the material arrangement can be tailored in accordance with the local requirements and the operational conditions [4]. Multi-material design offers a promising approach for the production of application-optimised components, where the material arrangement can be tailored in accordance with the local requirements and the operational conditions [4] At industrial scale, this method is widely used in sheet metal forming utilising technologies such as tailored blanks, clinching or clad rolling [5]. Only a limited number of investigations on this topic exists for bulk metal forming (i.a. forging)
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