Piezo-metal-composites in structural parts: Technological design, process simulation and material modelling

Subject is the development of a process chain for the production of semi-finished parts with an integrated sensor and actuator functionality and the forming of those to structural parts. Aiming on a non-damaging forming of the integrated piezo module, a swimming-bed inside the piezo-metal-composite is used. The hardening of adhesive surrounding the piezo module between the sheet-metal and the cover-layer takes place after the forming operation. The choice of an applicable adhesive and an application-oriented design of the compound influences the production process as well as the functionality of the compound. By employing a material model for the adhesive and a global forming simulation, including the loads taking effect on the piezo module, a comparison between the numerical simulation and experimental studies is possible. Furthermore, the results of simulation give information about the characteristics of the composite. A subsequent test of functionality will allow the definition of best suitable process parameters and the evaluation of the composites performance dependent on its design.