A Micro-Thermo-Mechanical Model for a Tailored Formed Joining Zone Deformed by Die Forging

authored by: Martina Baldrich, Fadi Aldakheel, Steffen Beese, Stefan Löhnert, Peter Wriggers
Abstract: In order to investigate new methodologies to produce light weight and load-adjusted hybrid solid components, a process chain using the technique of Tailored Forming is developed. Hereby, the two materials aluminium and steel are joined before being formed to a hybrid bearing bushing. A significant drawback of this technique is the weakened joining zone. This is due to the differences of material properties and the formation of an intermetallic phase at the joined zone, resulting in high stresses during the forming process that might lead to damage and failure. To achieve a high mechanical strength of the hybrid solid component, it is important to evaluate the sensitivity of different process parameters and to accurately adjust the material behaviour of the joining zone. Because of the strong dependence of the effective, macroscopic material behaviour on the thermomechanical influences at the microscopic level, the polycrystalline joining zone is investigated on the microscopic length scale. Material models are developed for each of the constituents steel and aluminium using the framework of dislocation density based crystal plasticity as well as an elastic material model for the brittle intermetallic phase. For the microscopic simulation of the die forging, a volume element of the joining zone is generated capturing the characteristic morphology of the different grains including their size distribution, non-convex shapes, elongation and volume fractions as well as the stochastic orientation of the grains. The microscopic boundary value problem is chosen to meet the macroscopically applied loads during the die forging of the bearing bushing.
Organisation(s): Institute of Continuum Mechanics
External Organisation(s): Technische Universität Dresden
Type: Conference contribution
No. of pages: 7
Publication date: 02.07.2019
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Ecology, Evolution, Behavior and Systematics, Ecology, Plant Science, Physics and Astronomy(all), Nature and Landscape Conservation
Electronic version(s): https://doi.org/10.1063/1.5112558 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{7cbe76560b6e4e9a8296b6ed087d1fd5,
title = "A Micro-Thermo-Mechanical Model for a Tailored Formed Joining Zone Deformed by Die Forging",
abstract = "In order to investigate new methodologies to produce light weight and load-adjusted hybrid solid components, a process chain using the technique of Tailored Forming is developed. Hereby, the two materials aluminium and steel are joined before being formed to a hybrid bearing bushing. A significant drawback of this technique is the weakened joining zone. This is due to the differences of material properties and the formation of an intermetallic phase at the joined zone, resulting in high stresses during the forming process that might lead to damage and failure. To achieve a high mechanical strength of the hybrid solid component, it is important to evaluate the sensitivity of different process parameters and to accurately adjust the material behaviour of the joining zone. Because of the strong dependence of the effective, macroscopic material behaviour on the thermomechanical influences at the microscopic level, the polycrystalline joining zone is investigated on the microscopic length scale. Material models are developed for each of the constituents steel and aluminium using the framework of dislocation density based crystal plasticity as well as an elastic material model for the brittle intermetallic phase. For the microscopic simulation of the die forging, a volume element of the joining zone is generated capturing the characteristic morphology of the different grains including their size distribution, non-convex shapes, elongation and volume fractions as well as the stochastic orientation of the grains. The microscopic boundary value problem is chosen to meet the macroscopically applied loads during the die forging of the bearing bushing.",
author = "Martina Baldrich and Fadi Aldakheel and Steffen Beese and Stefan L{\"o}hnert and Peter Wriggers",
note = "Funding information: The results presented here were obtained within the Collaborative Research Centre 1153 ”Process chain to produce hybrid high performance components by Tailored Forming” in the subproject C4 - project number 252662854. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project.; 22nd International ESAFORM Conference on Material Forming, ESAFORM 2019 ; Conference date: 08-05-2019 Through 10-05-2019",
year = "2019",
month = jul,
day = "2",
doi = "10.1063/1.5112558",
language = "English",
series = "AIP Conference Proceedings",
publisher = "American Institute of Physics Inc.",
number = "1",
editor = "Pedro Arrazola and {Saenz de Argandona}, Eneko and Nagore Otegi and Joseba Mendiguren and {Saez de Buruaga}, Mikel and Aitor Madariaga and Lander Galdos",
booktitle = "Proceedings of the 22nd International ESAFORM Conference on Material Forming",
}