Deep drawing of fiber metal laminates for automotive lightweight structures

Heggemann, Thomas; Homberg, Werner

doi:10.1016/j.compstruct.2019.02.047

Cited by 66 publications

(24 citation statements)

References 3 publications

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“…Studies have shown that the energy consumption of the automotive body is reduced by 6-8% for every 10% reduction in vehicle body quality [1][2][3]. Therefore, reducing the weight of the vehicle without reducing the overall performance can effectively reduce fuel consumption and pollution emissions.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Multi-Objective Optimization of Partition Cooling in Hot Stamping of the Automotive B-Pillar Based on RSM and NSGA-II

Cui

Wang

et al. 2020

Metals

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In this study, the simulation and optimization of the partition cooling in the hot stamping process was carried out for an automotive B-pillar through minimizing the maximum thickening rate and the maximum thinning rate located in the rapid and slow cooling zones. The optimization was implemented by investigating the process parameters such as friction coefficient, sheet austenitizing temperature, holding time, heating zone temperature, the upper binder force and the lower binder force. The optimal Latin hypercube design (OLHD), the response surface methodology (RSM) and the non-dominated sorting genetic algorithm (NSGA-II) were combined to establish the relationship between process parameters and form quality objectives. After multi-objective optimization, the maximum thickening rate and the maximum thinning rate of the slow cooling zone and rapid cooling zone were 11.1% and 12.4%, 4.7% and 7.1%, respectively. Afterwards, the simulation was performed according to the optimized parameter combinations to analyze the temperature field, microstructure, tensile strength, hardness, thickening rate and thinning rate, and forming quality. Moreover, the hot stamping test and experimental results showed that the microstructure of the ferrite and pearlite structure was uniformly distributed in the slow cooling zone, and its tensile strength reached 680 MPa, the elongation was 11.4% and the hardness was 230.56 HV, while the lath martensite structure was obtained in the rapid cooling zone, with tensile strength of up to 1390 MPa, elongation of about 7.0% and hardness reaching 478.78 HV. The results of thickness, microstructure, tensile strength and the hardness test correspond well with the simulation results.

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Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Multi-Objective Optimization of Partition Cooling in Hot Stamping of the Automotive B-Pillar Based on RSM and NSGA-II

Cui

Wang

et al. 2020

Metals

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“…Semi-finished FML products are often further processed by deep drawing, for example car body parts like cross members or the B-pillar [21]. During deep drawing, different stress conditions and relative movements between the laminates occur [21]. Consequently, the maximum bond strength between the laminates is not ideal for every area of the FML.…”

Section: Discussionmentioning

confidence: 99%

Time efficient laser modification of steel surfaces for advanced bonding in hybrid materials

Voswinkel

Kloidt

Grydin

et al. 2020

Prod. Eng. Res. Devel.

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Laser surface treatment of metals is one option to improve their properties for adhesive bonding. In this paper, a pulsed YVO4 Laser source with a wavelength of 1064 nm and a maximum power of 25 W was utilized to increase the surface area of the steel HCT490X in order to improve its bonding properties with a carbon fibre reinforced polymer (CFRP). Investigated was the influence of the scanning speed of the laser source on the bonding properties. For this purpose, the steel surfaces were ablated at a scanning speed between 1500 and 4500 mm/s. Afterwards the components were bonded with the adhesive HexBond™ 677. After lap shear tests were carried out on the specimen, the surfaces were inspected using scanning electron microscopy (SEM). The experiments revealed that the bonding quality can be improved with a high scanning speed, even when the surface is not completely ablated.

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“…One method of weight reduction is the application of lightweight constructions [5]. These assemblies consist of so-called multi-material systems, which are characterised by materials with different mechanical and geometrical properties and can thus be designed to suit specific requirements [6]. The different materials can be, for example, high strength steel and aluminium alloy sheets [7] and the geometrical properties can be characterised by varying sheet thicknesses and basic body geometries.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the influence of varying tumbling strategies on a tumbling self-piercing riveting process

Wituschek

Kappe

Lechner

2021

Prod. Eng. Res. Devel.

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The increasing demands for the reduction of carbon dioxide emission require intensified efforts to increase resource efficiency. Especially in the mobility sector with large moving masses, resource savings can contribute enormously to the reduction of emissions. One possibility is to reduce the weight of the vehicles by using lightweight technologies. A frequently used method is the implementation of multi-material systems. These consist of dissimilar materials such as steel, aluminium or plastics. In the production of these systems, the joining of the different materials and geometries is a central challenge. Due to the increasing demands on the joints, the challenges for the joining processes itself are also increasing. Since conventional joining processes are rather rigid and can only react to a limited extent to disturbance variables or changing process variables, new methods and technologies are required. A widely used conventional joining method with these properties is self-piercing riveting. Because of the rigid tool combination and the fact that the rivet geometry that can be used is related to the tools, the joining of multi-material systems requires tool and rivet changes during the process. In order to extend the process window of joining with self-piercing rivet elements, the process is enhanced with a tumbling kinematic of the punch. The integration of tumbling results in a significant increase in the adjustable process parameters. This enables a higher material flow control in the joining process through a specific tumbling strategy. The materials investigated are a steel and an aluminium alloy, which differ significantly in their mechanical properties and have many applications in automotive engineering, especially for structural car body components. The steel material is a galvanized HCT590X+Z dual-phase steel, which is characterised by a low yield strength, combined with high tensile strength and a good hardening behaviour. The aluminium alloy is an EN AW-6014. The precipitation-hardening alloy consists of aluminium, magnesium and silicon with a high strength and energy absorption capability. The objective of this work is to obtain a fundamental knowledge of the new tumbling self-piercing riveting process. With different mechanical properties and different sheet thicknesses of the joining partners, the influences of these parameters on the tumbling strategy of the riveting process are analysed. Such a tumbling strategy is based on the tumbling angle, the tumbling onset and the tumbling kinematics. These parameters are investigated in the context of the work for selected combinations of multi-material systems consisting of HCT590X+Z and EN AW-6014. With the variation of the parameters, the versatility of the process can be investigated and influences of the tumbling on the self-piercing riveting process can be identified. To illustrate the results, force–displacement curves from the joining process of the individual joints are compared and the geometry of the rivet undercut and rivet heads are geometrically measured. Furthermore, micrographs allow the analysis of the characteristic joint parameters interlock, residual sheet thickness and end position of the rivet head.

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Deep drawing of fiber metal laminates for automotive lightweight structures

Cited by 66 publications

References 3 publications

Numerical Simulation and Multi-Objective Optimization of Partition Cooling in Hot Stamping of the Automotive B-Pillar Based on RSM and NSGA-II

Numerical Simulation and Multi-Objective Optimization of Partition Cooling in Hot Stamping of the Automotive B-Pillar Based on RSM and NSGA-II

Time efficient laser modification of steel surfaces for advanced bonding in hybrid materials

Investigation of the influence of varying tumbling strategies on a tumbling self-piercing riveting process

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