Modelling of an induction heating process and resulting material distribution of a hybrid semi-finished product after impact extrusion

Behrens, Bernd‐Arno; Wester, Hendrik; Schäfer, Stefan; Büdenbender, Christoph

doi:10.25518/esaform21.574

Cited by 5 publications

(4 citation statements)

References 7 publications

(12 reference statements)

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“…Previous studies have shown that temperature control is of particular importance for the forming of hybrid steel-aluminium semi-finished products. Therefore, an inhomogeneous temperature field is set via induction heating [7]. The aim is to heat the steel as much as possible and keep the aluminium as cold as possible, to match the flow stresses of both materials.…”

Section: Methodsmentioning

confidence: 99%

“…Thermal material data was defined based on Simufact Forming 16 database. The relative permeability was determined by Behrens et al using the method described in [7]. The calculated inhomogeneous temperature field after induction heating is transferred to the semi-finished product of the impact extrusion model.…”

Section: Fig 2 Flow Curves For Various Temperatures and A Strain Rate...mentioning

confidence: 99%

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Modelling failure of joining zones during forming of hybrid parts

Wester¹

2023

Materials Research Proceedings

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Abstract. Combining diverse materials enables the use of the positive properties of the individual material in one component. Hybrid material combinations therefore offer great potential for meeting the increasing demand on highly loaded components. The use of hybrid pre-joined semi-finished products simplifies joining processes through the use of simple geometries. However, the use of pre-joined hybrid semi-finished products also results in new challenges for the following process chain. For example, the materials steel and aluminium may form brittle intermetallic phases in the joining zone, which can be damaged in the following forming process under the effect of thermo-mechanical loads and thus lead to a weak point in the final part. Due to their small thickness as well as their position in the component, the analysis of the joining zone is only possible by complex destructive testing methods. FE simulation therefore offers an efficient way to analyse the development of damage in the process design and to reduce damage by process modifications. Therefore, within this study a damage model based on cohesive zone elements is implemented in the FE software MSC Marc 2018 and calibrated using experimental local tensile tests performed under process relevant conditions.

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Section: Methodsmentioning

confidence: 99%

Section: Fig 2 Flow Curves For Various Temperatures and A Strain Rate...mentioning

confidence: 99%

Modelling failure of joining zones during forming of hybrid parts

Wester¹

2023

Materials Research Proceedings

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“…For an adequate numerical investigation of an induction heating process, the electromagnetic material data of the materials used are crucial. The required material properties for the 100Cr6 were taken from previous work [9]. Boundary conditions like current in the induction coil and the frequency were derived from experimental inductive heating tests, which are described in detail in [7].…”

Section: Methodsmentioning

confidence: 99%

Numerical Process Design for the Production of a Load-Adapted Hybrid Bearing Bushing

Uhe,

Wester,

Behrens

2023

KEM

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Due to increasing product requirements regarding lightweight, functional integration and resource efficiency, research into and use of hybrid parts are steadily increasing. Tailored Forming provides an innovative process chain for manufacturing hybrid parts by using pre-joined semi-finished products. In addition to the potentials, however, challenges also result in the production of hybrid components. In particular, the material combination of steel and aluminium is demanding due to strongly differing physical properties. An inhomogeneous temperature distribution within the pre-joined semi-finished part can be used to equalize flow properties during the forming process. However, processes are sensitive to temperature deviations resulting in critical stresses and failure of the final part. This study focuses on a process design of a hybrid bearing bushing consisting of the aluminium alloy EN-AW-6082 and the steel 100Cr6 using numerical simulation. First, a closed-die forging process is analysed regarding sensitivity to process fluctuations resulting in deviations in temperature distribution. To increase process stability, a new hollow forward-impact extrusion process is numerically designed and investigated regarding its potential to reduce critical stresses and thus the risk of part failure. Furthermore, a numerical model of inductive heating is used for the consideration of inhomogeneous temperature fields. Finally, hybrid bearing bushings are produced using closed-die forging and hollow-forward extrusion to evaluate numerical results.

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“…Steel and titan require forging temperatures that exceed the melting temperature of aluminium. To prevent melting of the aluminium, which destroys the component, special heating strategies were developed for several hybrid components [4,5]. The heating takes place locally using induction heating.…”

Section: Introductionmentioning

confidence: 99%

Comparative investigation of partial cooling methods for induction heating of hybrid bulk components for hot forming

Ince

2023

Materials Research Proceedings

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Abstract. The novel Tailored Forming process chain enables the combination of crucial properties of different materials by manufacturing hybrid components. Thereby, the limitations of monolithic components are surpassed. However, manufacturing hybrid bulk components introduces new challenges for hot forming. For example, when combining steel and aluminium, the main challenge is establishing and maintaining a temperature gradient in the component to match the differing flow stresses of the materials for a successful forging. For establishing the gradient, a particular heating strategy, including inductive heating of the steel and parallel partial cooling of the aluminium, is necessary. After reaching the target temperature, the heated component has to be transferred to the forging die by a robot while maintaining the essential temperature gradient. Therefore, a portable spray nozzle cooling system attached to the robot's end effector was designed in former work. This paper aims to validate spray nozzles for establishing a temperature gradient in a hybrid workpiece with a particular heating strategy compared to a currently used immersion cooling. For the validation, the nozzles will cool a hybrid steel aluminium shaft, whereby the nozzles' operation parameters influence on the temperature gradient will be investigated. Finally, the performance of the nozzles will be compared against the currently used immersion cooling.

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Modelling of an induction heating process and resulting material distribution of a hybrid semi-finished product after impact extrusion

Cited by 5 publications

References 7 publications

Modelling failure of joining zones during forming of hybrid parts

Modelling failure of joining zones during forming of hybrid parts

Numerical Process Design for the Production of a Load-Adapted Hybrid Bearing Bushing

Comparative investigation of partial cooling methods for induction heating of hybrid bulk components for hot forming

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