Deep drawing of metal sheets with integrated piezo-metal substructures

Piezo-metal substructures are a new approach for function integration in sheet metal parts. The surface of plane aluminum sheets is structured with parallel micro cavities by micro impact extrusion. Piezoceramic fibers are inserted in this cavities and a force-locked connection is established using joining by forming. The plane sheets are then shaped to a 3D-geometry by deep drawing. The process chain and the design constraints for the integration of the piezoceramic fibers are presented. Within the scope of the paper, results of a numerical and experimental study of micro impact extrusion, joining by forming and deep drawing are summarized. Thereby, good accordance between simulation and exper-iments has been achieved.

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