Umformtechnische Strukturierung metallischer Einleger im Folgeverbund für mediendichte Kunststoff-Metall-Hybridbauteile

Description

A major challenge in the production of polymer-metal hybrid parts using assembly injection molding is the limited media tightness due to the chemical incompatibility of the two materials. However, the use of metal inserts with defined surface structure has great potential to increase the tightness. Therefore, in this work the structuring of metal inserts by forming in a progressive die is investigated as a highly efficient manufacturing process. The aim of this work is to create an understanding of the manufacturability of structured inserts and to identify the process limits in regard to a functional design. Based on the investigations of rounding the cutting edges by embossing, the cross section of the metal insert was identified as the most important influencing variable on the die filling and thus on the forming accuracy. Within the investigations of the embossing of transverse grooves on the surface of the insert, a holistic understanding is created with regard to the resulting groove geometry and the axial and lateral elongation of the inserts. This is based on the examination of the material flow into axial and lateral directions. In this context, the resulting width in particular is strongly influenced by the prevailing flow restrictions. Finally, the results of the investigation of the structuring of metal inserts by forming are evaluated on the basis of the tightness of overmolded inserts and an increase in the sealing effect is shown. This contributes to the development and manufacturing of resilient electronic systems.