Simulation of a Forming Process for Joining a Piezo Aluminium Module
The fabrication of piezo aluminium composite modules for sensor and actor applications with mass production technologies is in the scope of the SFB/Transregio 39 PT-PIESA project funded by the (German Research Foundation). After forming of cavities with a width of 0.3 mm into aluminium sheets by micro impact extrusion and the insertion of 0.25 × 0.25 mm2 piezo rods, a joining of the rods into the material is necessary. For a minimization of a damping loss from the piezo material to the aluminium sheet the joining should be done without using any adhesives or intermediate layers. A strong contact between the two materials should be realized by a forming process. A tool with a flat plane is intended to be pressed onto the bars between the cavities to induce a lateral material flow which clamps the piezo rods. To avoid unnecessary damage or destruction of the piezo rods a simulation of the process was conducted. Applying COMSOL Multiphysics the resulting forces, stresses and deformations of the piezo rods resulting from the forming process were simulated.