Authors: Rosenthal, Stephan
Maaß, Fabian
Kamaliev, Mike
Hahn, Marlon
Gies, Soeren
Tekkaya, A. Erman
Title: Lightweight in automotive components by forming technology
Language (ISO): en
Abstract: Lightweight design is one of the current key drivers to reduce the energy consumption of vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications. In this paper, various forming processes to produce light parts are described. Material lightweight design is discussed, covering the manufacturing processes to produce hybrid components like fiber–metal, polymer–metal and metal–metal composites, which can be used in subsequent deep drawing or combined forming processes. Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented. Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet, profile and tube forming operations. To join those materials and/or dissimilar materials, new joining by forming technologies are shown. To economically produce lightweight parts with gears or functional elements, incremental sheet-bulk metal forming is presented. As an important part property, the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design. New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown. The possibilities of system lightweight design with forming technologies are presented. A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown. The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented. An in-depth understanding of the newly developed processes, methodologies and effects allows for a more accurate dimensioning of components. This facilitates a reduction in the total mass and an increasing performance of vehicle components.
Subject Headings: Forming technology
Lightweight design
Energy efficiency
Manufacturing processes
Subject Headings (RSWK): Umformen
Issue Date: 2020-07-31
Rights link:
Appears in Collections:Sonstige Veröffentlichungen

Files in This Item:
File Description SizeFormat 
Rosenthal2020_Article_LightweightInAutomotiveCompone.pdfDNB3.25 MBAdobe PDFView/Open

This item is protected by original copyright

This item is licensed under a Creative Commons License Creative Commons