Numerical simulation predicts failure of interphases

Figure 1: Tim Matthias and Anna Stakhieva using a TriboIndenter to investigate interphases in hybrids. (Photo: IFUM)

IFUM | Away from mono-material workpieces – towards load-adapted hybrid components: IFUM scientists are using numerical simulation methods to predict the maximum interphase load-bearing capacity and time to failure in tailored hybrid components.

Whether drive shafts or gear wheels: The trend is towards lightweight vehicle parts that are also able to withstand higher and higher loads. The solution is a combination of materials. The question is whether hybrids can withstand joint forming without rupturing at the joint? The Institute of Metal Forming and Metal Forming Machines (IFUM) is dealing with this question in the subproject C1 of the Collaborative Research Centre "Tailored Forming".

The load on the interphases is determined by tension and compression tests carried out on cylindrical specimens with differently arranged interphases. The test results are then used to create a model. The material behaviour in the intermediate layer is identified by interphase models based on cohesive elements. By this means, the researchers can predict the damage or failure of interphases – and avoid it in the future. Based on their expertise, the process design can be adapted in such a way that hybrids are able to withstand joint forming.

by Tim Matthias and Ilya Peshekhodov

Image gallery for this article

  • Figure 1: Tim Matthias and Anna Stakhieva using a TriboIndenter to investigate interphases in hybrids. (Photo: IFUM)
  • Figure 2: Hybrid bevel gear made of different steel alloys (left) and bearing sleeve made of steel and aluminium (right). (Graphic: IFUM)
  • Figure 3: The interphase is the most important thing – not only in this extrusion-moulded shaft. (Graphic: IFUM)
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