https://popups.uliege.be/esaform21/index.php?id=960 Publications of Auteurs Johanna Uhe fr 0 https://popups.uliege.be/esaform21/index.php?id=954 Multi-material solutions represent a promising approach for the production of load-optimised parts. The combination of material-specific advantages of different materials in a single component allows the fulfilment of conflicting requirements e.g. high performance and low weight. Fabrication of hybrid components is challenging due to the dissimilar properties of the individual materials and requires the development of suitable manufacturing technologies. The present paper deals with the simulation-based design of a forming process for the production of a suspension control arm consisting of steel and aluminium. With the focus on material flow, two forming concepts, open-die and closed-die forging, were investigated, in order to ensure the required material distribution similar to the final part. In addition, a tool analysis was carried out to avoid thermo-mechanical overload of the tool system. It was found that the required material distribution can be achieved with both forming concepts. However, a closed-die forging concept is not suitable because of the high stresses in the forging dies exceed the tool steel’s strength. Mon, 22 Mar 2021 10:30:37 +0100 Mon, 05 Apr 2021 18:22:43 +0200 https://popups.uliege.be/esaform21/index.php?id=954 https://popups.uliege.be/esaform21/index.php?id=919 Bulk metal components are often used in areas which are subjected to very high loads. For most technical components, a distinction between structural and functional areas can be made. These areas usually have very different loading profiles, sometimes with contradictory requirements. Nevertheless, nowadays almost only monomaterials are used for the production of bulk metal components. With increasing requirements towards more and more efficient products with lower weight, compact design and extended functionality, these materials are reaching their material-specific limits. A significant increase of product quality and economic efficiency can be expected exclusively with locally adapted properties by combining different materials within one component. In this regard, the focus of this contribution is the production of a hybrid pinion shaft made of the material combination steel (37CrS4) and aluminium (AW6082). The tool concept for extrusion of the hybrid preform, the simulation-based design of the forming process as well as the material characterisation are presented. With the help of the FE-simulation, different serially arranged semi-finished component geometries were investigated in order to minimise the occurring tensile stresses in the component during the extrusion process to prevent failure during forming. Mon, 22 Mar 2021 10:10:58 +0100 Mon, 29 Mar 2021 20:17:20 +0200 https://popups.uliege.be/esaform21/index.php?id=919