Bending behavior of structured steel sheets with undercuts for interlocking with Al die-cast metal

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING

International Journal of Material Forming Pub Date : 2023-11-09 DOI:10.1007/s12289-023-01797-6

Aron Ringel, Gerhard Hirt

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Abstract

Due to the current changes in mobility, lightweight design concepts continue to be of particular interest to the automotive industry. One form is the multi-material design, in which the advantageous properties of different materials are combined in one component. In this work, a component made of a steel sheet with stiffening structures of cast aluminum is considered. The joint is created by channel structures with undercuts on the surface of the steel sheet, into which the molten aluminum can flow. After solidification, an interlocking connection is created. The aim of this work is to investigate the influence of a bending operation on the surface structure before the die casting process. Numerical simulations and experimental validations were performed with different bending angles and radii as well as orientations between the channel structure and the punch. The results show that the undercuts on the outer radius are reduced by up to 75% by the bending operation, thus weakening the resulting joint. On the inner radius, the channel opening width narrows by up to 73% and can thus impede the filling with the melt.

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与铝压铸金属联锁用带凹口的结构钢薄板的弯曲性能

由于当前移动出行的变化，轻量化设计概念继续是特别感兴趣的汽车行业。一种形式是多材料设计，在这种设计中，不同材料的优点被组合在一个组件中。在这项工作中，考虑了一个由钢板与铸铝加强结构组成的部件。接头是由在钢板表面有凹口的沟道结构形成的，熔融铝可以流入其中。凝固后，形成一个联锁连接。本工作的目的是研究压铸过程前弯曲操作对表面结构的影响。数值模拟和实验验证了不同弯曲角度、半径和方向的通道结构与冲床。结果表明，弯曲操作使外半径上的凹痕减少了75%，从而削弱了接头。在内半径上，通道开口宽度缩小了73%，从而阻碍了熔体的填充。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.