Processing of hybrid composites

Forming of hybrid materials

Every construction material has specific properties which imply specific main fields of application. Often one single material cannot optimally meet the increasing component requirements regarding strength, stiffness, mass and damping behavior. Intelligent combination of various materials offers the potential of implementing the required component properties. Thus, metal materials are combined with other metal materials (e.g. tailored blanks of aluminum and steel), but metal materials are also combined with polymers or fiber-reinforced polymers. The processes of conventional sheet metal forming are predestined for economic, large-scale processing of these hybrid materials. Fraunhofer IWU develops customized process chains for forming of hybrid materials. This development comprises characterization of the hybrid materials and their individual components, process design (simulation, fundamental forming experiments), tool design, process control and process monitoring.

  • Process combination of deep drawing / injection molding
  • Process chains for mass production of components made of fiber-reinforced plastic / metal composites
  • Forming of metal-plastic composites filled with elastomers
  • Manufacturing of intrinsic hybrid composites by forming

  • Shortening of the process chain
  • Optimizing the interface properties by combining form connection and bonding connection
  • Flexibilization of process chains by modular plant technology
  • Continuous monitoring of material and component properties during production, processing, utilization stage up to recycling

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and technological dimensioning of processes, tools and machines

Development and evaluation of forming strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes

Machine technology

  • Hydraulic tryout press EHP4-1600 with multi-point die cushion and high-speed-system (press force: 16,000 kN, table size: 4,000 mm x 2,500 mm)
  • Multi-servopress MSP4-2000-2.5x1.2-400 (4 main drives, maximum compressive force 2,000 kN, ram speed 280 mm/s, table dimensions 2,500 x 1,200 mm)
  • Hydraulic double-column frame press HD 315 (press force: 3,150 kN, table size: 800 mm x 1,000 mm)
  • Hydraulic double-column press PYZ 250 with multi-point die cushion (press force: 2,500 kN, table size: 1,700 mm x 1,250 mm)
  • Hydraulic C-stand press CLDZ 250 with die cushion (press force: 2,500 kN, table size: 1,060 mm x 780 mm)

Software

  • Design: Creo Elements/Pro (Pro/ENGINEER), CATIA V5, Autodesk®, Inventor®, AutoCAD®
  • Simulation: PAM-STAMP, DEFORM, LS-DYNA, AutoForm, simufact, Abaqus, ANSYS®, ANSYS-CFX, ANSA, FEMM
  • Planning and evaluation of experiments: Cornerstone, Origin, MatLab
  • TOSCA
  • LS-OPT
  • Modern work stations (Windows)
  • Computing cluster (LINUX)

testing technology

  • Tensile testing machine Zwick 1475 with optical strain rate measurement, high temperature capability of up to 1,100 °C and a maximum force of 100 kN
  • Tensile testing machine Zwick FR 020TN with a maximum force of 20 kN
  • Biaxial tensile testing machine Zwick BX1-FR250SW.A1K with a maximum force of 30 kN (small specimens) and 250 kN (large specimens)
  • Tensile testing machine UTS 20 with vacuum / inert gas oven of up to 1,600 °C
  • High speed tensile testing machine Zwick-HTM 16020, testing speed in tension and compression up to 20 m/s, can be tempered up to 1,000 °C