Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

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OriginalspracheEnglisch
Seiten (von - bis)569-581
Seitenumfang13
FachzeitschriftProduction Engineering
Jahrgang14
Ausgabenummer5-6
Frühes Online-Datum7 Nov. 2020
PublikationsstatusVeröffentlicht - Dez. 2020

Abstract

This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

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Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing. / Behrens, Bernd Arno; Maier, Hans Jürgen; Poll, Gerhard et al.
in: Production Engineering, Jahrgang 14, Nr. 5-6, 12.2020, S. 569-581.

Publikation: Beitrag in FachzeitschriftArtikelForschungPeer-Review

Behrens, BA, Maier, HJ, Poll, G, Wriggers, P, Aldakheel, F, Klose, C, Nürnberger, F, Pape, F, Böhm, C, Chugreeva, A, Coors, T, Duran, D, Thürer, SE, Herbst, S, Hwang, JI, Matthias, T, Heimes, N & Uhe, J 2020, 'Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing', Production Engineering, Jg. 14, Nr. 5-6, S. 569-581. https://doi.org/10.1007/s11740-020-00992-7
Behrens BA, Maier HJ, Poll G, Wriggers P, Aldakheel F, Klose C et al. Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing. Production Engineering. 2020 Dez;14(5-6):569-581. Epub 2020 Nov 7. doi: 10.1007/s11740-020-00992-7
Behrens, Bernd Arno ; Maier, Hans Jürgen ; Poll, Gerhard et al. / Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing. in: Production Engineering. 2020 ; Jahrgang 14, Nr. 5-6. S. 569-581.
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title = "Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing",
abstract = "This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.",
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note = "Funding Information: The results presented were obtained in the subprojects A1, A2, B2, B3, C1, C3 and C4 of the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming”-252662854. The authors thank the Deutsche Forschungsgemeinschaft (German Research Foundation, DFG) for their financial support. ",
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T1 - Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

AU - Behrens, Bernd Arno

AU - Maier, Hans Jürgen

AU - Poll, Gerhard

AU - Wriggers, Peter

AU - Aldakheel, Fadi

AU - Klose, Christian

AU - Nürnberger, Florian

AU - Pape, Florian

AU - Böhm, Christoph

AU - Chugreeva, Anna

AU - Coors, Timm

AU - Duran, Deniz

AU - Thürer, Susanne E.

AU - Herbst, Sebastian

AU - Hwang, Jae Il

AU - Matthias, Tim

AU - Heimes, Norman

AU - Uhe, Johanna

N1 - Funding Information: The results presented were obtained in the subprojects A1, A2, B2, B3, C1, C3 and C4 of the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming”-252662854. The authors thank the Deutsche Forschungsgemeinschaft (German Research Foundation, DFG) for their financial support.

PY - 2020/12

Y1 - 2020/12

N2 - This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

AB - This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

KW - Bulk metal forming

KW - Finite element method

KW - Hybrid components

KW - Intermetallic phases

KW - Tailored forming

KW - Virtual element method

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U2 - 10.1007/s11740-020-00992-7

DO - 10.1007/s11740-020-00992-7

M3 - Article

AN - SCOPUS:85095584304

VL - 14

SP - 569

EP - 581

JO - Production Engineering

JF - Production Engineering

SN - 0944-6524

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ER -

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