Simulation of a Forming Process for Joining a Piezo Aluminium Module

M. Hackert, S.F. Jahn, and A. Schubert
Chemnitz University of Technology, Chair Micromanufacturing Technology, Germany
Published in 2010

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.