In all areas of technology, the demand for high-quality, competitive and more valuable products is rising steadily. One approach to increase the value of manufactured products is the integration of electronic components in load carrying structures. These new products, which combine electrical and mechanical components synergistically, are called smart products. They consist of a passive structure and integrated electronics or smart materials. In addition to their mechanical properties they are also able to sense, to actuate or to transmit energy or data. The resulting product architecture requires both a mechanical and an electronic design in order to save subsequent assembly costs. Since further components are required to evaluate and control as well as to supply energy, all of those components need to be connected and integrated into the smart product. However, the main prerequisite for the marketability is the possibility of low-cost manufacturing and a robust mass production. Nowadays processes for the manufacturing of smart products do not fulfill the requirements for a sustainable mass production in a satisfying way as long as metallic structures are used. The authors deploy the forming technologies roll forming and sheet metal hydroforming to form sheets with applied flat electronics. Since the components are applied prior to the forming process, small and difficult to access installation spaces can be used effectively in the product architecture. The incremental bulk forming process rotary swaging is employed to integrate piezoceramics during the forming procedure without any additional joining elements. Challenges resulting from the chosen integrative manufacturing approach are the prevention of new kinds of failure modes and additional requirements for defined residual stress states. These challenges lead to extended process design requirements, which will be discussed in the paper in detail.
[1]
Soon Young Yoon,et al.
Superhard Ti–Si–N coatings by a hybrid system of arc ion plating and sputtering techniques ☆
,
2002
.
[2]
R. Neugebauer,et al.
Piezo-Module-Compounds in Metal Forming: Experimental and Numerical Studies
,
2010
.
[3]
Peter Groche,et al.
Smart structures assembly through incremental forming
,
2011
.
[4]
Peter Groche,et al.
Sheet metal hydroforming of functional composite structures
,
2011,
Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring.
[5]
Toshihisa Nishioka,et al.
Hybrid numerical methods in static and dynamic fracture mechanics
,
1999
.
[6]
Fritz Klocke,et al.
Design methodology for hybrid production processes
,
2011
.
[7]
A. Olowinsky,et al.
Laser Assisted Joining of Plastic Metal Hybrids
,
2011
.