Papers by Author: Verena Psyk

Abstract: When manufacturing joints of dissimilar materials thermal technologies as welding reach their limits. Impact welding by electromagnetic forming is a promising alternative because undesired heating of the parts and related disadvantages are avoided. In this process impact parameters need to be adjusted to each specific joining task, but cannot be settled directly. Thus, a two-step methodology is suggested for the process design: First the influence of the impact parameters and the surface preparation on the joint properties is investigated using a model experiment. Joint properties are characterized by metallographic investigations. Parallel to this, the influence of the adjustable process parameters and the equipment on the workpiece acceleration and the impact properties is analyzed. Then the results of both investigation paths are combined and conclusions regarding a target-oriented adjusting of the impact parameters via the process parameters are drawn. In the paper first results considering the model experiment and the analysis of the electromagnetic expansion process are presented and joints manufactured by electromagnetic expansion are characterized.

Abstract: In recent years a steadily growing interest in applying lightweight construction concepts could be observed. This development is accompanied by an increasing demand for innovative forming strategies suitable for extending the forming limits of the typical lightweight materials. Deep drawing combined with an integrated electromagnetic calibration step is an example of such a technology. The feasibility and potential of this process combination is analyzed on the basis of a demonstrator part from the automotive industry. Thereby, aspects related to the practicability of the electromagnetic forming process itself are regarded as well as points related to the deep drawn preform. The concept of a 3D-coil insert, integrated into a deep drawing punch in order to realize the calibration in the deep drawing process, is introduced and based on the experimental results, conclusions regarding the applicability of the process combination are drawn.