In this work, the development of a hybrid lightweight automotive chassis control arm is demonstrated. It includes the development of a new simulation method for designing metal — LFT (long fiber-reinforced thermoplastics) rehybrid parts and the new hybrid forming method for its manufacture. Beginning with the original geometry of a series steel chassis control arm, the design was optimized for the hybrid forming process where a steel sheet part is reinforced by an LFT rib structure, and both parts are joined by an LFT layer. For this purpose, a new FE optimization process chain was established. The thickness of the sheet metal and LFT layers, the geometry and thickness of the ribs of the hybrid control arm could be determined to meet both mechanical and light weight requirements. Afterwards, a suitable tooling concept and process for the hybrid forming were developed and tested. The forming behavior of two different steel grades along with an LFT was demonstrated and analyzed with the help of 3D measurement techniques and relevant section cuts. Finally, a weight reduction of nearly 20 % compared to the original component was realized with the hybrid forming process.

在这项工作中，展示了混合轻型汽车底盘控制臂的开发。它包括开发一种新的金属设计模拟方法——LFT（长纤维增强热塑性塑料）再混合部件及其制造的新混合成型方法。从系列钢制底盘控制臂的原始几何形状开始，该设计针对混合成型工艺进行了优化，其中钢板部件由 LFT 肋结构加固，两个部件通过 LFT 层连接。为此，建立了新的有限元优化流程链。可以确定金属板和 LFT 层的厚度、混合控制臂肋的几何形状和厚度，以满足机械和轻量化要求。然后，开发并测试了适合混合成型的模具概念和工艺。借助 3D 测量技术和相关截面切割，演示和分析了两种不同钢种以及 LFT 的成形行为。最后，与原始组件相比，混合成型工艺实现了近 20% 的重量减轻。