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Active media based forming for the in-situ manufacturing of metal and plastic composite structures

Wirkmedienbasiertes Umformen zur in-situ Fertigung von Metall-Kunststoff-Hybridbauteilen
: Albert, Andre´; Drossel, Welf-Guntram; Zorn, Wolfgang

Hausmann, J. M.; Siebert, M. ; Deutsche Gesellschaft für Materialkunde e.V. -DGM-, Oberursel:
Euro Hybrid Materials and Structures 2014. Proceedings CD-ROM : International conference. 10 - 11 April 2014, Stade, Germany
Stade: DGM, 2014
ISBN: 978-3-88355-402-0
Conference Euro Hybrid Materials and Structures <2014, Stade>
Conference Paper
Fraunhofer IWU ()
deep drawing; injection moulding; media-based forming; hydroforming; hybrid; in situ; merge; plastic

Metal/plastic hybrid structures are an efficient solution for making the best use of materials at every point in a product. This article shows the state of the art and current developments for the manufacture of metal/plastic composites in the fields of production and research. There are three production technologies: insert technology, outsert technology and metal/plastic hybrid technology. In all technologies the metal parts are produced separately from the plastic parts. The injection moulding process is only used for forming the plastic parts and for joining. The process chains involved are very long. Based on the state of the art in the research a concept for a new process combination, which will be developed at the Fraunhofer IWU in cooperation with the Technische Universität Chemnitz, will be presented. The aim is to combine deep drawing, injection moulding and media-based forming in one die. This process will produce one part for each press stroke, thus increasing production efficiency and achieving very small tolerances for parts.