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Forming based on operating media for the in-situ manufacture of metal/plastic composite structures

Presentation held at Lightweight Structures, International MERGE Technologies Conference, IMTC 2013; 24-25 October 2013, Chemnitz
Herstellung von Metall-/Kunststoff-Hybridbauteilen durch wirkmedienbasiertes Umformen
: Albert, Andre´

Präsentation urn:nbn:de:0011-n-2664929 (1.0 MByte PDF)
MD5 Fingerprint: 7a55d58ae3573480833c1a38d5f3a196
Erstellt am: 12.11.2013

2013, 18 Folien
International MERGE Technologies Conference (IMTC) <1, 2013, Chemnitz>
Vortrag, Elektronische Publikation
Fraunhofer IWU ()
Metall; Kunststoff; Hybrid; Merge; in situ; Tiefziehen; Spritzgießen; PIF; polymer injection forming; wirkmedienbasierte Umformung; IHU; IHB; Hydroforming; Innenhochdruck-Umformung

In the "Merge" project a forming process for the in situ manufacture of metal/plastic composite structures will be developed. The process is a combination of deep drawing, injection moulding and media based forming in one die. The project is splited into two phases. In the first phase 2013-2014 the technical basis will be created and tested on a cup with a polymer injected plastic inner part. Aluminum, steel and hybrid laminates will be used as sheet materials and PA 6 as plastic component. In the second phase 2015-2017 the process should be transferred to a production orientated part.
After the state of the art three technologies for the manufacturing of metal plastic composite parts are existing: the insert technology, the outsert technology and the metal plastic hybrid technology. In all technologies the metal or sheet parts where produced separately from the plastic parts. The injection moulding process is only used for forming the plastic parts and for joining the parts.
The "Merge" process is divided into two steps. First operation is the deep drawing process to generate the preform of the metal part. Then the injection moulding process takes place. The plastic melt will be used for the injection moulding and also as an active media for metal forming.
A real deep drawing process with blank holder and die cushion should be realized. So the process had to be installed on a deep drawing press together with an injection moulding bolt on unit.