Numerical investigation on the deep drawing of sheet metals with an additively applied coating
MÄRZ Raphaela, HAFENECKER Jan, BARTELS Dominic, SCHMIDT Michael, MERKLEIN Mariondownload PDF
Abstract. A promising approach to meet ecological and economical challenges in production industry is the combination of additive manufacturing and forming, which enables the production of hybrid parts. The fusion of the two technologies has the potential to use the benefits of both process classes. One example for the combination of additive manufacturing and forming is a process chain consisting of laser-based directed energy deposition (DED-LB/M) to apply a wear resistant coating on a sheet metal and a subsequent deep drawing process to achieve the final geometry of the component. However, the presence of the local reinforcement influences the subsequent sheet metal forming process. In order to gain more knowledge about the process chain a numerical approach is performed. In this work, the influence of a coating using Bainidur® AM applied by DED-LB/M on the formability of the case hardening steel 16MnCr5 in a deep drawing process is evaluated. For this purpose, a numerical model is built and validated by comparison with experimental results. The finite-element-model serves as the basis for the investigation on the influence of the location of the additively applied coating on the deep drawing process and also enables a deeper understanding of the process.
Additive Manufacturing, Forming, Hybrid Parts
Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: MÄRZ Raphaela, HAFENECKER Jan, BARTELS Dominic, SCHMIDT Michael, MERKLEIN Marion, Numerical investigation on the deep drawing of sheet metals with an additively applied coating, Materials Research Proceedings, Vol. 28, pp 919-928, 2023
The article was published as article 100 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
 European Commission, A European Green Deal, 2022. https://ec.europa.eu/info/strategy/priorities-2019-2024/european-green-deal_en
 A.E. Tekkaya, N.B. Khalifa, G. Grzancic, R. Hölker, Forming of Lightweight Metal Components: Need for New Technologies, Procedia Eng. 81 (2014) 28-37. https://doi.org/10.1016/j.proeng.2014.09.125
 F. Klocke, Manufacturing Processes 4, Springer Berlin Heidelberg, Berlin, Heidelberg, 2013.
 I. Gibson, D. Rosen, B. Stucker, Additive Manufacturing Technologies, Springer New York, New York, NY, 2015.
 M. Merklein, D. Junker, A. Schaub, F. Neubauer, Hybrid Additive Manufacturing Technologies – An Analysis Regarding Potentials and Applications, Phys. Procedia 83 (2016) 549-559. https://doi.org/10.1016/j.phpro.2016.08.057
 M. Bambach, A. Sviridov, A. Weisheit, J. Schleifenbaum, Case Studies on Local Reinforcement of Sheet Metal Components by Laser Additive Manufacturing, Metals 7 (2017) 113. https://doi.org/10.3390/met7040113
 DIN EN ISO 6892-1:2020-06, Metallic materials – Tensile testing – Part 1: Method of test at room temperature, Beuth publishing, Berlin.
 C. Tome, G.R. Canova, U.F. Kocks, N. Christodoulou, J.J. Jonas, The relation between macroscopic and microscopic strain hardening in F.C.C. polycrystals, Acta Metall. 32 (1984) 1637-1653. https://doi.org/10.1016/0001-6160(84)90222-0
 J.E. Hockett, O.D. Sherby, Large strain deformation of polycrystalline metals at low homologous temperatures, J. Mech. Phys. Solid. 23 (1975) 87–98. https://doi.org/10.1016/0022-5096(75)90018-6
 M. Kreß, D. Bartels, M. Schmidt, M. Merklein, Material Characterization of Hybrid Components Manufactured by Laser-Based Directed Energy Deposition on Sheet Metal Substrates, KEM 926 (2022) 80-–89. https://doi.org/10.4028/p-3vlx01
 J. Hafenecker, T. Papke, F. Huber, M. Schmidt, M. Merklein, Modelling of Hybrid Parts Made of Ti-6Al-4V Sheets and Additive Manufactured Structures, in: B.-A. Behrens, A. Brosius, W. Hintze, S. Ihlenfeldt, J.P. Wulfsberg (Eds.), Production at the leading edge of technology, Springer Berlin Heidelberg, Berlin, Heidelberg, 2021, pp. 13-22. https://doi.org/10.1007/978-3-662-62138-7_2