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Department of Mechanical Engineering

Process for Manufacturing Composite Components by a Combination of Deep Drawing and Cold Forging

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  • Massivumformung
  • Umformtechnische Grundlagenforschung
  • Technologieentwicklung
a-d) Process with counter holder, e) Asymmetrically and f) Symmetrically encapsulated component © IUL
a-d) Process with counter holder, e) Asymmetrically and f) Symmetrically encapsulated component
Funding German Research Foundation (DFG)
Project 289596321
Contact Johannes Gebhard M. Sc.

Draw-forging is the combination of deep drawing and full-forward rod extrusion in one process step. This allows the production of composite components with a lightweight core and a steel encapsulation, combining the benefits of different materials. In the second phase of the research project, the product spectrum is extended by increasing the maximum drawing ratio through intermediate annealing and deep drawing in multiple steps. To encapsulate specific sections, another process route is investigated, where a pierced sheet is expanded, deep-drawn over the corresponding section, and extruded together with the core. Slight local changes in friction as well as geometric inaccuracies of the blank or the eccentricity of the die set lead to unstable expansion and prevent the process from being successful. With a new contoured counter holder, the process (see Figure a-d) can be stabilized and the repeatability can be significantly increased. Figure f shows a component with a free tip and partial encapsulation.