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

authored by: Bernd Arno Behrens, Hans Jürgen Maier, Gerhard Poll, Peter Wriggers, Fadi Aldakheel, Christian Klose, Florian Nürnberger, Florian Pape, Christoph Böhm, Anna Chugreeva, Timm Coors, Deniz Duran, Susanne E. Thürer, Sebastian Herbst, Jae Il Hwang, Tim Matthias, Norman Heimes, Johanna Uhe
Abstract: 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.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Institute of Materials Science
Institute of Machine Elements and Engineering Design
Institute of Continuum Mechanics
Type: Article
Journal: Production Engineering
Volume: 14
Pages: 569-581
No. of pages: 13
ISSN: 0944-6524
Publication date: 12.2020
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s11740-020-00992-7 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{b77b20101673471fb9cb1cd089c9d4a9,
title = "Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing",
abstract = "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.",
keywords = "Bulk metal forming, Finite element method, Hybrid components, Intermetallic phases, Tailored forming, Virtual element method",
author = "Behrens, {Bernd Arno} and Maier, {Hans J{\"u}rgen} and Gerhard Poll and Peter Wriggers and Fadi Aldakheel and Christian Klose and Florian N{\"u}rnberger and Florian Pape and Christoph B{\"o}hm and Anna Chugreeva and Timm Coors and Deniz Duran and Th{\"u}rer, {Susanne E.} and Sebastian Herbst and Hwang, {Jae Il} and Tim Matthias and Norman Heimes and Johanna Uhe",
note = "Funding Information: The results presented were obtained in the subprojects A1, A2, B2, B3, C1, C3 and C4 of the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming”-252662854. The authors thank the Deutsche Forschungsgemeinschaft (German Research Foundation, DFG) for their financial support. ",
year = "2020",
month = dec,
doi = "10.1007/s11740-020-00992-7",
language = "English",
volume = "14",
pages = "569--581",
journal = "Production Engineering",
issn = "0944-6524",
publisher = "Springer Verlag",
number = "5-6",
}