Hybride formschlüssige Strukturverbindungen in Leichtbaustrukturen aus Stahlblech und Aluminiumdruckguss

摘要

The topic of this paper is the characterisation and numerical modelling of advanced sheet metal components reinforced by light metal cast structures (SADH). The modelling is focused on full car simulation. One major aspect is the discretisation of form closure connections between sheet metal and aluminium cast structure which realise the compound between both materials. A SADH structure consists of a steel sheet metal and an integrated stiffening structure of aluminium. For the manufacturing process a perforated sheet metal is placed in a high pressure die casting tool before the casting. During the casting the holes of the sheet metal are filled with aluminium and a fixed form closure connection is generated. At a demonstrator structure of a SADH typical characteristics are named and analysed. Resulting from different thermal expansion coefficients and manufacturing temperatures residual stresses and distortion are analysed. Static loading tests are carried out to analyse the mechanical performance. For a virtual development process a numerical model of a SADH is generated. To model the material characteristics thermal loading test become necessary for the sheet metal. The sheet metal is exposed to a short and high thermal treatment during the high pressure die casting process which has to be considered for the material card. At a special form closure specimen manufacturing details are investigated. This specimen is further used to generate a loading profile of form closure connections under different conditions. Based on the test data a numerical model of the form closure connections is developed on full car modelling level. The verified form closure model is then transferred to the SADH structural model. Concluding the correlation between numerical calculation and experiments is shown on the SADH structural tests.