A Combined Experimental and Numerical Approach to the Laser Joining of Hybrid Polymer – Metal Parts

Mithilfe laserbasierter generativer Fertigungsverfahren (Laser Additive Manufacturing – LAM) ist es möglich, potentiell komplexe Bauteilgeometrien variantenreich herzustellen. Damit kann Gewicht eingespart werden und Funktionen sind integrierbar. In Kombination mit Automatisierungs- und innovativer Lasertechnik in der Schweiß- und Schneidapplikation lässt sich dieser Prozess wirtschaftlich nutzen. Durch pulverbettbasierte Lasergenerierverfahren können metallische Bauteile schichtweise aufgebaut werden, jedoch ist die Auswahl der Werkstoffe limitiert. Im Forschungsprojekt StaVari (Additive Fertigungsprozesse für komplexe Produkte in variantenreicher und hochfunktionaler Stahlbauweisen) vereinen sich die neuesten Erkenntnisse in Material-, Laser-, Füge- und Automatisierungstechnik, um modernen Anforderungen der Automobilbranche in der Massenfertigung sowie bei der Medizintechnik in der Kleinserie gerecht zu werden.   Laser Additive Manufacturing LAM has the potential to generate complex geometries. Through this weight reduction, functional integration and multi-variant production is possible. In combination with automation and innovative laser technology applicated in welding and cutting, this process can be used economically. With powderbed based laser additive manufacturing metal parts can be built up layer by layer. However selection of available metals is limited. In the project StaVari latest findings in material-, laser-, joining and automation technology are joint by qualified partners to meet modern automotive demands in mass production and medicine technology for small batch series.

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Optimisation of Springback Predicted by Experimental and Numerical Approach by Using Response Surface Methodology

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.6-8.753 ◽

2005 ◽

Vol 6-8 ◽

pp. 753-762

Author(s):

R. Bahloul ◽

Phillippe dal Santo ◽

Ali Mkaddem ◽

A. Potiron

Keyword(s):

Response Surface ◽

Sheet Metal ◽

Design Method ◽

Fem Simulation ◽

Numerical Approach ◽

Tool Geometry ◽

Nose Radius ◽

Element Analysis ◽

Metal Parts ◽

Sheet Metal Parts

Bending has significant importance in the sheet metal product industry. Moreover, the springback of sheet metal should be taken into consideration in order to produce bent sheet metal parts within acceptable tolerance limits and to solve geometrical variation for the control of manufacturing process. Nowadays, the importance of this problem increases because of the use of sheet-metal parts with high mechanical characteristics (High Strength Low Alloy steel). This work describes robust methods of predicting springback of parts in 3D modelling subjected to bending and unbending deformations. Also the effects of tool geometry in the final shape after springback are discussed. The first part of this paper presents the laboratory experiments in wiping die bending, in which the influence of process variables, such as die shoulder radius, punch-die clearance, punch nose radius and materials properties were discussed. The second part summarises the finite element analysis by using ABAQUS software and compares these results with some experimental data. It appeared that the final results of the FEM simulation are in good agreement with the experimental ones. An optimisation methodology based on the use of experimental design method and response surface technique is proposed in the third part of this paper. That makes it possible to obtain the optimum values of clearance between the punch and the die and the optimum die radius which can reduce the springback without cracking and damage of product.

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