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Simulation study on the influence of process parameters on the hybrid forging quality of a control arm

Hybrid forging combines forming of bulky and sheet metal elements in one process step. During the forming of the bulky and sheet metal elements a joining operation is initiated by the energy provided by the forging operation. Thereby component areas with high loads can be designed using a bulky element whereas areas with lower loads can be designed using a sheet metal element. In consequence, significant weight reductions as well as energy savings within the forging process are achievable. The paper presents the development of a hybrid forging process, using a control arm as demonstration part. By the aid of Finite Element Analysis computations the interactions between the main process parameters and the target value process quality are being derived. It will be shown that the bulky element's shape has a major impact on further process parameters and that the temperature is crucial for material bonding.