Investigation of the joining zone displacement of cross-wedge rolled serially arranged hybrid parts

Within the Collaborative Research Centre (CRC) 1153 “Tailored Forming “the manufacturing of hybrid bulk components is investigated. Therefore, a process chain consisting of joining, forming, milling and quality control has been established by multiple subprojects. Within subproject B1 of the CRC forming of hybrid parts by the incrementally forming cross-wedge rolling (CWR) process is investigated. The superior aim is to determine process limits and capabilities, when forming parts consisting of different materials joined by varying technologies.

In this paper, the investigation of cross-wedge rolling of serially arranged hybrid parts made of steel and aluminium is described. The focus of the research presented in this publication is the displacement of the joining zone of hybrid parts due to the cross-wedge rolling process. Therefore, finite element simulations have been developed, that allow the investigations of hybrid solid components. After simulation of various variations of the cross-wedge rolling process, i.e. differently shaped tools and forming velocities, experimental trials were carried out with identical parameter sets. A comparison of simulation and experiment, showed that the simulation model is capable of describing the cross-wedge rolling process of hybrid parts. The standard deviation of the displacement of the joining zone between simulation and experimental trials is 8.8% with regard to all investigated cases.