Joining using forming processes in the field of bulk metal forming is currently experiencing a renaissance both within research projects in academia and industrial manufacturing processes. One main challenge of such research activities is any improvement of joint strength. In contrast to conventionally joined interference fits, such components can be manufactured without heating or thermal loads. Within framework of the priority program SPP 1640 of the German Research Foundation, a common lateral extrusion process for a solid internal part and an external tube actually is being developed at the Institute for Metal Forming Technology, Stuttgart. Aim of this project is to manufacture a form-closed as well as force-closed joint composed by a high strength external material and a light weight internal material for light-weight components. The present work describes numerical investigations of this process and shows aspects of process development. This includes, among other things, development of a new tool concept, which provides divided punches to determine the influence of different punch motion on the forming and joining process. Spring back behavior, induced residual stress distribution and occurring contact area depending on different material combinations are also investigated. Moreover, the process limits regarding component geometry and force requirement are shown.
Extrusion Process Development of Light-Weight Interior & Exterior Parts for High Speed Train on Aluminum Alloys
