Hybrid Bulk Forming of Plastic-Metal-Compounds

• Applicants: Professor Dr.-Ing. Christian Bonten; Professor Dr.-Ing. Mathias Liewald
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Joining and Separation Technology
• Term: since 2021
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 461883580

An improvement of the resource efficiency of complex metal forming components in the automotive industry can be achieved by adapting the materials to the prevailing load cases. Hybrid components and especially plastic-metal compounds fulfil these requirements by combining entirely different material properties. However, modelling of such processes poses serious challenges due to the different material characteristics. Barely any publications are available on the use of plastics as pressure medium for cold forging. The aim of the proposed project is to build a thorough knowledge base on the use of plastic material as a pressure medium in bulk forming processes. Plastics are already being used in back injection molding to deform sheet metal components. In this case, however, the pressure inside the plastic component is quite low (< 300 MPa) compared to bulk forming processes. The use of preheated thermoplastics as pressure material in bulk metal forming is not yet well enough investigated. Considering the plastic component, the challenges are pressure resistance, the compounding as well as the tooling and the resulting filler material orientation. The bonding strength is mainly affected by the elastic behavior in the plastic-metal-interface. The following hypothesis is drawn: A plastic phase satisfying the posed requirements can be manufactured and subsequently be used to act as a pressure medium in bulk forming of plastic-metal hybrids. In a first step, the materials are defined. The properties of the plastic phase can be varied in a wide range by compounding strategies. The materials are characterised and the property adaptions of the plastic phase are analysed. A simplified model process featuring joining and forming of both components within one step will be developed. Coupled simulative investigations by varying material properties and process parameters give more profound information about the processing technology. Finally, the operating characteristics of the hybrid components will be investigated experimentally.

• DFG Programme: Research Grants