Due to the current changes in mobility, lightweight design concepts continue to be of particular interest to the automotive industry. One form is the multi-material design, in which the advantageous properties of different materials are combined in one component. In this work, a component made of a steel sheet with stiffening structures of cast aluminum is considered. The joint is created by channel structures with undercuts on the surface of the steel sheet, into which the molten aluminum can flow. After solidification, an interlocking connection is created. The aim of this work is to investigate the influence of a bending operation on the surface structure before the die casting process. Numerical simulations and experimental validations were performed with different bending angles and radii as well as orientations between the channel structure and the punch. The results show that the undercuts on the outer radius are reduced by up to 75% by the bending operation, thus weakening the resulting joint. On the inner radius, the channel opening width narrows by up to 73% and can thus impede the filling with the melt.

由于当前移动性的变化，轻量化设计概念仍然受到汽车行业的特别关注。一种形式是多材料设计，其中不同材料的有利特性被结合在一个组件中。在这项工作中，考虑了由钢板制成的具有铸铝加固结构的部件。接缝是由钢板表面带有底切的通道结构形成的，熔融铝可以流入其中。凝固后，形成互锁连接。这项工作的目的是研究压铸工艺前弯曲操作对表面结构的影响。使用不同的弯曲角度和半径以及通道结构和冲头之间的方向进行数值模拟和实验验证。结果表明，弯曲操作使外半径上的底切减少了 75%，从而削弱了最终接头的强度。在内半径上，通道开口宽度缩小达 73%，因此会阻碍熔体填充。