Development of Combined Manufacturing Technologies for High-Strength Structural Components

Abstract

Abstract. Novel manufacturing technologies for high-strength structural components of aluminium allow a local modification of material properties to respond to operational demands. Machining and finishing processes for changing material properties like deep rolling or rubbing are to be combined to a single process step. The intention is the controlled adjustment of the component's properties by the modification of its subsurface. For that purpose the essential understanding of the interaction mechanisms of the basic processes turning, deep rolling and rubbing is necessary. Influences of the tool geometry as well as of the process parameters on the material properties are investigated. The results will be extended by parameter studies within numerical simulations. Thereafter, combinations of the basic processes in process sequences are analyzed to their ability to modify the subsurface properties. In consideration of these results, a prototypic combined turn-rolling tool is developed Introduction Aluminium and its alloys are important construction materials for lightweight applications. High strength at low density of selected aluminium alloys enables the construction of a variety of structural and planar components [1,2]. Aluminium parts used in such a way must bear high wear and oscillating mechanical loads during application. In practice the most stressed regions in technical components are often found in the subsurface, e. g. by bending, torsion and corrosion loads. Therefore, the properties of the component's subsurface are of outstanding importance [3,4]. These properties are considerably influenced by the applied machining procedure. Different states of residual stress, hardness, surface roughness and microstructure can be realized. A controlled influence on the subsurface by the machining process can improve the component's properties and life cycle [5].