Umformtechnische Herstellung hybrider Lagerbuchsen*/Manufacturing of Hybrid Bearing Bushings

Behrens, Bernd Arno; Bouguecha, Anas; Vučetić, Mladen; Huskic, Aziz; Uhe, Johanna; Frischkorn, Conrad; Matthias, Thorsten; Stakhieva, A.; Duran, Deniz; Thürer, Susanne Elisabeth; Golovko, O.; Klose, Christian

doi:10.37544/1436-4980-2016-10-69

Cited by 5 publications

(2 citation statements)

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“…Although the application of tailored blanks is already state of the art in sheet metal forming, the use of hybrid semi-finished workpieces is not common in bulk metal forming. For this reason, the aim of the Collaborative Research Centre 1153 is to realise new process chains to produce hybrid solid components with load-adjusted properties using semifinished workpieces joined prior to forming [1].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

Thürer

Uhe

Golovko

et al. 2017

KEM

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Within the scope of the Collaborative Research Centre (CRC) 1153 novel process chains for the production of hybrid solid components by Tailored Forming are developed at the Leibniz Universität Hannover. The combination of e. g. aluminium with steel allows to produce hybrid compounds with wear-resistant functional surfaces and reduced weight. In these process chains, joining takes place as the first step to produce hybrid semi-finished products by friction welding, cladding, ultrasonic assisted laser welding or co-extrusion, which are subsequently subjected to various forming processes such as forging or impact extrusion. The coaxially joined hybrid semi-finished components investigated in this work were produced by means of the lateral angular co-extrusion (LACE) process using the aluminium alloy EN AW-6082 and the case-hardening steel 20MnCr5. These semi-finished products shall be suited to produce hybrid bearing bushings by die forging in a subsequent process step. Initial investigations for the determination of the process parameters and the appropriate tool geometry were made using a steel rod. In future investigations, a steel tube will replace the steel rod in order to produce hybrid semi-finished products, which can be fully integrated into the process chain. The mechanical properties of the profile were determined at different positions along its length. For this purpose, the quality of the joining zone between aluminium and steel as a function of the profile position was examined by means of push-out tests. Moreover, the mechanical properties of the aluminium component’s longitudinal weld seam were determined by micro-tensile-tests.

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Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

Thürer

Uhe

Golovko

et al. 2017

KEM

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“…The CRC 1153 addresses this inadequate knowledge and bridges the knowledge gap by means of a thorough basic research. In [10,11], Behrens et al present challenges arising due to different material properties as well as their possible solutions for heating and forming strategies.…”

Section: Die Forging Of Coaxially Arranged Hybrid Workpiecesmentioning

confidence: 99%

FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

Behrens

Bouguecha

Bonk

et al. 2017

KEM

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Multi-material solutions offer numerous benefits producing tailored-made hybrid components with enhanced application-optimized properties contrary to conventional monolithic parts. However, designing of corresponding manufacturing processes is often challenging due to various technical aspects. This paper represents a process route for the manufacturing of a hybrid bevel gear by means of tailored forming technology with a focus on die forging and describes the main challenges within the forming stage. Due to local material-specific properties, uncommon material flow and complex geometry of the final part, an individual forming tool system with a geared die was accurately designed. Besides the forming tool system, the FE-based design of the forging process as well as the necessary material characterisation will be presented. Finally, the initial results of the experimental forging investigations are shown.

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Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

Behrens

Maier

Poll

et al. 2020

Prod. Eng. Res. Devel.

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This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

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Umformtechnische Herstellung hybrider Lagerbuchsen*/Manufacturing of Hybrid Bearing Bushings

Cited by 5 publications

References 0 publications

Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

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