Modelling failure of joining zones during forming of hybrid parts

authored by: Hendrik Wester, Eugen Stockburger, Simon Peddinghaus, Johanna Uhe, Bernd Arno Behrens
Abstract: Combining diverse materials enables the use of the positive properties of the individual material in one component. Hybrid material combinations therefore offer great potential for meeting the increasing demand on highly loaded components. The use of hybrid pre-joined semi-finished products simplifies joining processes through the use of simple geometries. However, the use of pre-joined hybrid semi-finished products also results in new challenges for the following process chain. For example, the materials steel and aluminium may form brittle intermetallic phases in the joining zone, which can be damaged in the following forming process under the effect of thermo-mechanical loads and thus lead to a weak point in the final part. Due to their small thickness as well as their position in the component, the analysis of the joining zone is only possible by complex destructive testing methods. FE simulation therefore offers an efficient way to analyse the development of damage in the process design and to reduce damage by process modifications. Therefore, within this study a damage model based on cohesive zone elements is implemented in the FE software MSC Marc 2018 and calibrated using experimental local tensile tests performed under process relevant conditions.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Pages: 717-726
No. of pages: 10
Publication date: 19.04.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: General Materials Science
Electronic version(s): https://doi.org/10.21741/9781644902479-78 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{b3a874f870d141959097ef8aa9907867,
title = "Modelling failure of joining zones during forming of hybrid parts",
abstract = "Combining diverse materials enables the use of the positive properties of the individual material in one component. Hybrid material combinations therefore offer great potential for meeting the increasing demand on highly loaded components. The use of hybrid pre-joined semi-finished products simplifies joining processes through the use of simple geometries. However, the use of pre-joined hybrid semi-finished products also results in new challenges for the following process chain. For example, the materials steel and aluminium may form brittle intermetallic phases in the joining zone, which can be damaged in the following forming process under the effect of thermo-mechanical loads and thus lead to a weak point in the final part. Due to their small thickness as well as their position in the component, the analysis of the joining zone is only possible by complex destructive testing methods. FE simulation therefore offers an efficient way to analyse the development of damage in the process design and to reduce damage by process modifications. Therefore, within this study a damage model based on cohesive zone elements is implemented in the FE software MSC Marc 2018 and calibrated using experimental local tensile tests performed under process relevant conditions.",
keywords = "Cohesive Zones, Local Tensile Tests, Numerical Modelling, Pre-Joined Hybrid Semi-Finished Parts",
author = "Hendrik Wester and Eugen Stockburger and Simon Peddinghaus and Johanna Uhe and Behrens, {Bernd Arno}",
note = "Funding Information: The results presented in this paper were obtained within the Collaborative Research Centre 1153 “Process chain to produce hybrid high-performance components by Tailored Forming” in the subproject C01. The authors would like to thank the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG, 252662854) for the financial and organisational support of this project. The authors would like to thank the subproject B03 for friction welding of hybrid semi-finished parts and the subproject C04 for support regarding the damage model.; 26th International ESAFORM Conference on Material Forming, ESAFORM 2023 ; Conference date: 19-04-2023 Through 21-04-2023",
year = "2023",
month = apr,
day = "19",
doi = "10.21741/9781644902479-78",
language = "English",
isbn = "9781644902462",
series = "Materials Research Proceedings",
publisher = "Association of American Publishers",
pages = "717--726",
editor = "Lukasz Madej and Mateusz Sitko and Konrad Perzynsk",
booktitle = "Material Forming",
}