Harms A, Römisch D, Reisacher D, Lechner M, Merklein M (2025)
Publication Status: Submitted
Publication Type: Unpublished / Preprint
Future Publication Type: Journal article
Publication year: 2025
DOI: 10.2139/ssrn.5811719
Increasing demands for lightweight design and functional integration in modern production technology require innovative manufacturing processes. Multi-material systems offer a high potential to face these challenges by reducing weight while maintaining strength. A new approach of an orbital forming process to join dissimilar materials while simultaneously achieve a local thickening offers a reduced number of required parts since there is no need for auxiliary elements and high material efficiency due to near-net-shape design. In this context, this research provides the design and validation of a numerical simulation model for joining by orbital forming with local material accumulation in a single step. The hybrid component consists of an inner aluminum blank of EN AW-5754 and an outer steel ring made of DP600 both with an initial sheet thickness of 3.0 mm. The steel ring features cut-outs on the inside to provide a form closure in tangential direction. The primary aim of the simulation model is to predict and analyze the material flow during the forming process as well as the resulting stress states to evaluate the force closure. Furthermore, preliminary experimental investigations show a significant influence of the positioning of the steel cut-outs in relation to the locally thickened areas on the joint formation. This effect will be further analyzed using the numerical model to gain a deeper understanding of the cause-and-effect relations. Based on experimental investigations the numerical model will be validated by comparing the resulting sheet thickness distribution and the geometric and mechanical properties at the joint for several parameter combinations. The validated numerical model will then be used for an optimization of the joint positioning regarding the resulting material flow in the joint area. This approach provides a fundamental understanding on the mechanisms affecting this combined forming and joining process.
APA:
Harms, A., Römisch, D., Reisacher, D., Lechner, M., & Merklein, M. (2026). Numerical investigation of an orbital forming process to join dissimilar materials with local material accumulation. (Unpublished, Submitted).
MLA:
Harms, Arnold, et al. Numerical investigation of an orbital forming process to join dissimilar materials with local material accumulation. Unpublished, Submitted. 2026.
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