Process chain simulation of laser cladding and cold metal forming

Lightweight construction is still an important driver for innovations in production technologies. Recent developments in Laser Metal Deposition (LMD) and forming technology allow the production of lightweight sheet metal components with locally adapted properties, reducing the weight of parts. For example, using laser cladding, it is possible to reinforce critical areas of a sheet metal component, while other areas can still remain untouched and thus consume less material, reducing the overall weight of the component. Conventional production of such reinforced structures would require expensive and time consuming machining steps. However, especially if it comes to sheet metal components that are to be mechanically formed, the induction of heat during laser cladding might lead to undesired properties of the final product due to distortion, residual stresses as well as changed material properties. Such effects can be investigated by means of structural welding simulation, but, if it comes to process chains, i.e. reinforced metal sheets that undergo forming processes, a process chain simulation covering forming and cladding steps is desirable. This approach would also answer the question of preferred process sequences. This article presents an approach for such a process chain simulation for a demonstrator made of aluminium EN AW 6016 undergoing one laser cladding and one cold forming process. The simulation considers the influence of the process sequence (forming-cladding vs. cladding-forming) and helps to select the proper process sequence as well as predicts properties of the final product.