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Specific mechanical properties of superplastically formed components and resulting applications for vehicles

Vorobyov, Kyrylo and Danchenko, Valentyn and Beeh, Elmar and Kopp, Gundolf (2011) Specific mechanical properties of superplastically formed components and resulting applications for vehicles. THERMEC 2011, 01-05. Aug. 2011, Quebec, Canada.

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Abstract

The technical requirements to produce parts as light as possible with more complex geometries are ever increasing in recent years in automotive industries, rail vehicle and aerospace. Manufacturing technologies such as super-plastic metal forming, which had been considered as a niche technology earlier, is now gaining greater technical relevance for industrial size production. The parts that have been generated through super-plastic forming in innovative vehicle for example Mercedes SLS AMG reflect the industrial activity in this area. Manufacturability of thin-walled structures enables lightweight design. Also the tool and manufacturing costs are lower in comparison. However, the main challenge could be found in maintaining exact process parameters. There is a large research potential in super-plastic forming; from the determination of optimal material data through process simulation to manufacturing of real parts and their characterization. In the framework of the project international Bureau of the Federal Ministry of Education and Research UKR005/08 “Manufacture of parts with special properties” a preliminary research work has been carried out. The scientific challenge lies in the characterisation of forming properties of light metal alloys in super-plastic forming. In this preliminary research, the “full factorial experiment” methodology has been applied, regression equations have been developed and a mathematical model derived. This shows interrelationship between mechanical properties of the material and the variable process parameters, leading to material characterization. Hence advantages of cost and time have been achieved; the important parameters for the design of parts through super-plastic forming are determined. The analytical results are then verified with finite element method ─ simulations and through experiments with general parts.

Document Type:Conference or Workshop Item (Speech, Paper)
Title:Specific mechanical properties of superplastically formed components and resulting applications for vehicles
Authors:
AuthorsInstitution or Email of Authors
Vorobyov, KyryloKyrylo.Vorobyov@dlr.de
Danchenko, ValentynNationale Metallurgische Akademie der Ukraine
Beeh, ElmarElmar.Beeh@dlr.de
Kopp, GundolfGundolf.Kopp@dlr.de
Date:1 August 2011
Refereed publication:Yes
In ISI Web of Science:No
Status:Published
Keywords:Severe plastic deformation, Al-, Mg- Alloys, superplastische Blechumformung.
Event Title:THERMEC 2011
Event Location:Quebec, Canada
Event Type:international Conference
Event Dates:01-05. Aug. 2011
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Terrestrial Vehicles
DLR - Research area:Transport
DLR - Program:V BF - Bodengebundene Fahrzeuge
DLR - Research theme (Project):V - Multi Material Design Strukturen (old)
Location: Stuttgart
Institutes and Institutions:Institute of Vehicle Concepts > Lightweight and Hybrid Design Methods
Deposited By: Kyrylo Vorobyov
Deposited On:05 Apr 2011 09:47
Last Modified:20 Sep 2012 10:57

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