DEVELOPMENT AND NUMERICAL VALIDATION OF COMBINED FORMING PROCESSES FOR PRODUCTION OF HYBRID PARTS

This paper gives an overview about different one-shot processes of hybrid forming and joining of semi-finished products using conventional forming presses. An example of forming with a variothermal tool is given by forming a sandwich structure. Different aspects of the forming process are addressed, including the interlayer formation during the process. Here, the objectives are the complete impregnation of the fibres, the consolidation and a firm bond. It is shown, that in contrast to that, the objective when forming a sandwich sheet is to prevent delamination. For forming a hybrid battery tray, a process was developed that combines the advantages of organic sheet forming and compression molding. In order to predict the quality of the bonding of the glass mat reinforced thermoplastic to the organic sheet the temperature evolution is numerically analysed.