The current upheaval in the mobility sector has created many new framework conditions and requirements for vehicle components among vehicle manufacturers. For example, with the introduction of heavy batteries in motor vehicles, the topic of lightweight construction is no less relevant than in previous decades. In addition to lightweight materials, lightweight design is of particular importance. Often, highly stressed components cannot be made from alternative materials with a lower density due to the required strength. In these cases, it makes sense to use hollow structures, for example, in order to save weight. Forming processes are particularly in demand for the production of such components. These offer decisive advantages, particularly from a manufacturing point of view, such as an uninterrupted grain flow, high surface quality and material utilization as well as the work hardening of the material that occurs during the forming process.
Gear body before and after the joining process (left) and preform of a piston pin with structurally optimised inside (right)
The current developments in automotive engineering have as their key objectives the reduction of fuel consumption and, consequently, CO2 emissions. The construction of vehicles with reduced weight represents a pivotal technology for automakers, maintaining significant importance for the field of electromobility as well. Efforts in lightweight body construction have led to the development of modern, high-strength, and easily manufacturable steel bodies with at least equivalent lightweight potential compared to aluminum. Nevertheless, these achievements have not been replicated in other components, such as the vehicle drivetrain, which is now produced by a multitude of companies and industries.
In response to this challenge, a consortium has been established by German solid forming companies, their Industrial Association for Solid Forming (IMU, Hagen), and steel manufacturers (www.massiverleichtbau.de). This initiative involves 10 research institutes, which have been divided into five sub-projects. The primary objective is to reduce weight while maintaining high durability expectations through the use of new materials, targeted improvements in component design, and modified manufacturing methods. Initial significant weight reduction potentials have been demonstrated using existing materials and processes. Building on this foundation, the consortium's projects focus on exploring entirely new lightweight potentials in the drivetrain and chassis, interdisciplinary connecting specialties across the entire supply chain involved in these efforts.
Duration: 05.2015 - 10.2018