Extending the potentials of draw-forging

Abstract Composite components combine the benefits of different materials, leading to improved product properties, enhanced resource- and energy efficiency and widening the product spectrum. Draw-forging is the unique combination of deep-drawing and cold forging, where a core material is encapsulated within a thin sheet metal blank. Previously, the basic draw-forging process only allowed covering of the shaft tip, and the covered length was limited by the maximum drawing ratio of the sheet. In this work, the different failure types, including tearing of the sheet, asymmetric encapsulation, and the development of a gap in the transition zone were investigated numerically and experimentally and the axial encapsulation length is increased significantly. The usage of anisotropic sheet material leads to a form fit and enhances the bond strength in draw-forged hybrid components. An alternative process route in which a pierced sheet is utilized to partially cover a specific section of a shaft was also developed. The process route was stabilized with a novel contoured counter holder to ensure high repeatability.