Characterization of contact tensions during incremental forming of metal

composites

R. Neugebauer, S. Meinel *, R. Glaß, M. Popp

Fraunhofer Institute for Machine Tools and Forming Technology IWU – Germany –

ABSTRACT: The realization of light weight design of components with local, load adapted properties is a major goal
in the development of new manufacturing and processing methods of metal composite materials. A main challenge in
the manufacturing of compounds by forming consists in the realization of the necessary conditions for the initiation of
the diffusion process and the generation of metallic bonding. A combination of high contact tensions with specific
forming conditions such as temperature distribution and surface enlargement is required in order to initiate the diffusion
of atoms during the forming process. The article presents FEM-simulation and investigation of contact and forming
conditions of aluminum-magnesium composites with respect to an incremental forming method. The characteristics of
the compound materials, surface enlargement and local forming conditions as well as temperature gradients are
important factors for the diffusion processes. The investigation of contact conditions during compound formation is a
prerequisite for the further design of forming methods and the base for new approaches of generating composites of two
light metal alloys into products with favorable properties such as high specific strength and corrosion resistance.

KEYWORDS: metal composite materials, incremental forming, FEM simulation

1 INTRODUCTION substance transport across phase interface is possible

only if the system is comprised of a series of mixed
Automotive lightweight construction becomes increasing crystals – which is given in the present system [1].
important due to the environment protection. Weight Basically the creation of compounds requires the specific
savings of 100 kg are connected .with a carbon dioxide setting of technological parameters which are necessary
reduction of about.8.4 g/km. Only for Germany the to affect the enhancement of surface comprehensive
amount of the total road performance adds up to 5.6 strength in the binding area. Furthermore the so called
billion km, showing the enormous importance of threshold energy is essential for the initiation of a
material savings and lightweight production.. diffusion process [2]. This amount of energy is available,
A promising alternative is due to the application of light if an elevated forming temperature is applied which is,
metals, first of all the utilization of magnesium. on the other hand, necessary for the balance of ductility
Compared to its density magnesium is characterized by between the different materials.
relatively high stability. The drawback of a very low
corrosion resistance can be eliminated by using a 2.2 Approach
metallic compound with a second, more resistant
material. The research presented in this paper is devoted Based on more general, qualitative details in the
to the behavior of metallic compounds undergoing literature the fundamentals are obliged to quantify. This
forming operations. The materials of the composite are becomes feasible only if process-specific parameter
the basically used alloys AZ31 and AlMgSi1. fields can be represented within differentiated
quantitative and numerical models. That requires a
sophisticated description of the factors acting locally
2 Creation of Composites within the interface by means of measurable variables. It
2.1 General was therefore an objective to develop a test arrangement
facilitating the creation of a composite material in a way
Results from previous research confirm that there are
that allows a variation of defined parameters. This
chemical prerequisites for diffusion in the solid phase for
requires FEM-simulations for the spin extrusion process
an aluminum/magnesium pairing to be met. Usually,
____________________
* Corresponding author: Dr. Stefan Meinel
Fraunhofer Institute for Machine Tools and Forming Technology IWU
Address
Reichenhainer Str. 88
09126 Chemnitz – Germany
Phone: +49-371-53 97 12 09 – Fax: +49-371-53 97 12 98
to appoint the local stresses and strains in the binding stationary start-up phase, which seems hard to pass
layer. Furthermore was carried out lateral extrusion through.
experiments (see chap. 4.1) for identification of main
parameters. The spin extrusion tests targets at the
evaluation of the theoretical research (see chap. 4.2, 4.3).
The theoretical model has to account for the following
questions based on former research [3]:
- the maximal enlargement of surface in the binding area
- the predetermination of the Al/Mg material distribu-
tion in the cross section
- positioning of the binding layer depending the optimal
stress during the forming process
- a largely prevention of sliding in the binding zone.
Regarding to this needs and respecting the complex
conditions of incremental forming it is reasonable to use
numerical simulation to get a better understanding of Figure 1: 3D model of spin extrusion
process.
Therefore, the available 3D results can be associated
3 Simulation with the pre-forming phase. Nevertheless, simulations
give an instructive and detailed insight in the complex
3.1 Modelling thermo-mechanical relations of the two phase spin
As an example of incremental forming spin extrusion extrusion process. Figure 2 shows the radial and angular
turned out to be a challenging task for simulation. displacement, the temperature (caused by dissipative
Typical features of the numerical model are: heating, heat conduction, heat loss to environment and at
Geometry and physics of the process is 3D, processes are tools contact) and the strain rate.
very “long”, the zones of load impact are localized, but In a radial cutting plane of the work-piece (figure 3)
not fixed in time and numerical grids are subjected to local interface-gaps located between the rollers can be
massive deformation and degradation. identified. Periodically opening and closing gaps during
So, large models, numerous time steps and adaptive the forming process is not supportive for the formation
remeshing with high frequency are mandatory for an of a metallic compound. Compared are two simulations
effective simulation. Because of this we have to accept with different temperatures of the punch.
some simplifications. This concerns limitations of the The ongoing run ahead of the outer material layer does
mesh refinement, where numerical grids with more then not allow precise estimations of the stress and
50.000 nodes are likely to slow down the computation, deformation state within the interface contact area.
nevertheless CPU-times of about 10-20 hours for the A precondition for the development of an inter-metallic
simulation of one rotation of the work piece are normal. phase is to guarantee a fixed temperature at the interface.
Furthermore the tools (rollers and punch) are considered Caused by the heat transfer coefficient, there is a notable
as rigid bodies and they are modeled as surfaces without jump in the temperature distribution at the interface, if
inner heat transport. the punch is at RT. With a punch warmed up to the
In previous investigations (see for example [7], [8] the forming temperature of 300° C this difference can be
authors have made substantial efforts relating the significantly reduced (figure 3). The temperature of the
simulation of single phase spin extrusion. The code rollers is less important because of a much smaller
primarily used for this work was MSC.SuperForm. In the contact zone between roller and work-piece.
current problem this algorithm has not approved to be
well suited, because of severe convergence problems
caused by the large contact area between the layers.
Finally DEFORM-3D has been preferred to treat with
the 3D simulation. For a more simple 2D treatment of
some special aspects the system ABAQUS has been used

3.2 3D Simulations
The pre-forming process of double layer spin extrusion
is considerably prolonged due to the outflow balancing
between the two metallic phases. The first part of the
extrusion process is characterized by a run ahead of the
outer (aluminum) layer. Practically, it takes some time to
stabilize the continuous outflow of both phases. In terms
of technological parameters we have to perform more
than fifty rotations of tools until a steady process is Figure 2: Axial displacement, angular displacement,
attained. For the simulation this implies a very long non- temperature, strain rate, after t=1 s process time
 efficient geometry assuring an economic and statistically
ensured analysis of the parameters.

Figure 3: Temperature distribution and interface

alignment for simulations with different punch
temperatures (radial cut)

3.3 2D Simulation
Considering the problems of simulating the steady state
of the forming process a simplified 2D model was
established and analyzed. The goal of this investigation
was to estimate the influence of the layer thickness of the
outer aluminum layer and of the number and geometry
of the rollers (1-4) on the deformation process. The Figure 5: Analogy experiment – lateral extrusion
benefits of such simple model are purchased by the
drawback of neglecting axial deformations. Only The test arrangement shown in Figure 5 is based on the
qualitative results are expected. process principle of lateral extrusion, i.e. the material
Some conclusions of these numerical test cases are: flow is in transverse direction to the punch movement.
The cyclic overrun of the rollers induces a periodic load The aluminum or magnesium specimen in the heatable
change in the contact area between the layers. The mold halves is formed by two punches moving towards
intensity of the load changes increases with decreasing each other at equal speed so that a pressing process is
thickness of the outer layer (7.5 mm, 5.0 mm and 2.5 developing symmetrically to the partition plane; a
mm). composite specimen with a pin offset by 180° is molded
The effect of cyclic separation (lift-off) between the due to the transverse material flow. The interface of the
layers was observed in all cases under consideration, it is merged materials is situated in the partition plane.
amplified in the case of minor layer thickness. The use A micro structural examination of the interface (Fig. 6)
of multiple rollers with the same roller radius not demonstrated that a homogeneous interface is formed
entirely minimizes or prevents the lift-off effect. between magnesium and aluminum under the given test
Plastic deformation due to rolling is largely concentrated conditions [5] [6].
on the near surface regions. Therefore, in the case of a
thick outer layer (of 5.0 mm or 7.5 mm) the interface
region remains largely undeformed (see figure 4).

Figure 6: Microstructure of the interface; left: SEM photo

of the interface indicating the percent-by-weight
distribution of aluminum and magnesium; right: EDXS
Figure 4: v Mises stress for different layer thickness of analysis in mapping mode
AlMgSi1(right: Al- layer 2.5mm, right: Al-layer 7.5mm)
4.2 Spin Extrusion
4 Experiments
Spin extrusion as a partial rotating forming process is
4.1 Execution and Results of Lateral Extrusion used to produce axially symmetric hollow parts from
The analogy experiment described below established the solid semi-finished bars. Hollow forms are created by a
preconditions for proving interface reactions between mandrel shaping the inner contour and spinning rollers
aluminum and magnesium under forming conditions. In rotating on the outer coating of the raw bar. As a result,
addition, there is an opportunity to specifically examine the material yields axially against the feed direction, thus
the composite-enhancing effect of a multitude of forming a cup wall (Fig. 7).
parameters [4, 5, 6]. Compared to spin extrusion, the Spin Extrusion is carried out with a numerical controlled
specimens used here are distinguished through a cost- test machine BDM 2000 at the IWU (Fig. 8).
 influence of layer thickness and die design on the
interface conditions.
Further investigations should examine more closely the
mandrel preconditions for the development of an inter-metallic
phase during incremental forming.
roller

ACKNOWLEDGEMENT
The studies outlined in this article were financed by
funds of the German Research Community (DFG) that
we would like to thank for their support at this point.
mas s ive bar

REFERENCES
Figure 7: Spin Extrusion
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Figure 9: AlMgSi1-AZ31composite right: axial cut; left:

microscopy of the binding area 120-times magnified

5 CONCLUSIONS
Lateral extrusion is an adequate attempt for generating a
bond between aluminum and magnesium. A transfer of
basic results to incremental forming was not yet feasible.
3D simulations of double layer spin extrusion give an
insight in the complex thermo-mechanics of the process
but no distinct information about the bonding process.
With a simplified 2D model it is possible to analyze the