Deep drawing effects of structured steel sheets with undercuts by cold rolling for interlocking joints
Aron Ringel, Karl Johann Tilly, David Bailly
Abstract. The multi-material approach combines the advantageous properties of different materials to reduce weight while maintaining key performance characteristics. However, joining of different material classes (e.g. steel, aluminum or plastics) remains challenging and new joining techniques have been developed to overcome the existing limitations. Metal-metal joints can be achieved by hybrid casting. Here, one material is added in a liquid state, which provides the possibilities of hidden joint areas and more complex geometries. In a similar way, direct assembly processes are used for metal-plastic joints. Both variants use surface structures to create an interlocking connection. One option to create structured surfaces is a modified cold rolling process that creates channel-like surface structures with undercuts. As automotive components have complex shapes, additional forming might be used before the casting or molding. This paper aims to show how cold rolled structures affect the forming limit up to failure during deep drawing and how the additional forming process affects those structures. DC04 steel sheets were structured by cold rolling, cut into plates, and deep drawn into cross cups. The design of experiments included unstructured sheets for benchmarking, as well as sheets with longitudinal and diagonal surface structures, with the structures positioned on both the inside and outside of the cups. The blank holder force and punch movement were adjusted to determine the forming limit. The plastic strains were estimated by a finite element (FE) ABAQUS model. Cross-section samples from the cup’s bottom, wall, and radius were analyzed to assess changes in the structure geometry.
Keywords
Interlocking, Multi-Material, Structured Cold Rolling, Deep Drawing, FE-Modelling
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Aron Ringel, Karl Johann Tilly, David Bailly, Deep drawing effects of structured steel sheets with undercuts by cold rolling for interlocking joints, Materials Research Proceedings, Vol. 54, pp 1432-1441, 2025
DOI: https://doi.org/10.21741/9781644903599-155
The article was published as article 155 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.
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