Lightweight design is one of the current key drivers to reduce the energy consumption of vehicles.Design methodologies for lightweight components,strategies utilizing materials with favorable specific properties and h...Lightweight design is one of the current key drivers to reduce the energy consumption of vehicles.Design methodologies for lightweight components,strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications.In this paper,various forming processes to produce light parts are described.Material lightweight design is discussed,covering the manufacturing processes to produce hybrid components like fiber-metal,polymer-metal and metal-metal composites,which can be used in subsequent deep drawing or combined forming processes.Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented.Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet,profile and tube forming operations.To join those materials and/or dissimilar materials,new joining by forming technologies are shown.To economically produce lightweight parts with gears or functional elements,incremental sheet-bulk metal forming is pre-sented.As an important part property,the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design.New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown.The possibilities of system lightweight design with forming technologies are presented.A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown.The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented.An in-depth understanding of the newly developed processes,methodologies and effects allows for a more accurate dimen-sioning of components.This facilitates a reduction in the total mass and an increasing performance of vehicle components.展开更多
基金Open Access funding provided by Projekt DEAL.The authors thank the German Research Foundation(DFG)for the financial support of the ongoing projects:Collaborative Research Centre TRR 188“Damage Controlled Forming Processes”(Project number 278868966-TRR 188)Forming of additively manufactured sandwich sheets with optimized core structures(Project number 317137194)+5 种基金Process combination of single point incremental forming and laser powder deposition for the manufacturing of lightweight components(Project number 385276922)Joining by die-less hydroforming with outer pressurization(Project number 350070123)Process combination of combined deep drawing and cold forging(Project number 289596321)Kinematic profile bending with locally heated cross section(Project number 408302329)Product property controlled multi-stage hot sheet metal forming(Project number 424334660)TRR 73:Manufacturing of Complex Functional Components with Variants by Using a New Sheet Metal Forming Process-Sheet-Bulk Metal Forming(Project number 68237143).
文摘Lightweight design is one of the current key drivers to reduce the energy consumption of vehicles.Design methodologies for lightweight components,strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications.In this paper,various forming processes to produce light parts are described.Material lightweight design is discussed,covering the manufacturing processes to produce hybrid components like fiber-metal,polymer-metal and metal-metal composites,which can be used in subsequent deep drawing or combined forming processes.Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented.Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet,profile and tube forming operations.To join those materials and/or dissimilar materials,new joining by forming technologies are shown.To economically produce lightweight parts with gears or functional elements,incremental sheet-bulk metal forming is pre-sented.As an important part property,the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design.New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown.The possibilities of system lightweight design with forming technologies are presented.A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown.The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented.An in-depth understanding of the newly developed processes,methodologies and effects allows for a more accurate dimen-sioning of components.This facilitates a reduction in the total mass and an increasing performance of vehicle components.
