Finite element analysis for sheet metal reinforced hybrid structures produced via non-kinematical constraint manufacturing processes

authored by: B. A. Behrens, A. Chugreev, J. Moritz, F. Bohne, H. Schulze
Abstract: With reference to the challenges in the automotive industry like fuel economy or weight reduction, new hybrid materials are being developed and applied for established as well as new components. One approach to achieve less weight while retaining adequate mechanical characteristics is the combination of different materials [1, 2]. In [1] the advantages of hybrid structures consisting of fibre reinforced plastics (FRP) in combination with sheet metal inlays are investigated. For the manufacturing of these FRP-metal structures new innovative production concepts are needed. The present contribution deals with FE based process design of the manufacturing process for hybrid components with nonkinematical knitting rotation. Within the process, the metallic inlays will be entirely wrapped by the thermoplastic matrix. Using this method, a form- and material fitted structure is generated by process integration. Air locking defects can be suppressed by the rotational tool motion through an improved local contact pressure. Applying a rotational motion influences the flow direction and fibre orientation in positive manner. An extensive material characterization has been carried out. In order to describe the flow behaviour of the polymer component, viscosity data is needed. Therefore, experimental investigations are carried out and provided for the FE simulation.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Publication date: 2018
Publication status: Published
ASJC Scopus subject areas: Ceramics and Composites
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{3b33fdb2808a4c0fbd9d5a4744d501c5,
title = "Finite element analysis for sheet metal reinforced hybrid structures produced via non-kinematical constraint manufacturing processes",
abstract = "With reference to the challenges in the automotive industry like fuel economy or weight reduction, new hybrid materials are being developed and applied for established as well as new components. One approach to achieve less weight while retaining adequate mechanical characteristics is the combination of different materials [1, 2]. In [1] the advantages of hybrid structures consisting of fibre reinforced plastics (FRP) in combination with sheet metal inlays are investigated. For the manufacturing of these FRP-metal structures new innovative production concepts are needed. The present contribution deals with FE based process design of the manufacturing process for hybrid components with nonkinematical knitting rotation. Within the process, the metallic inlays will be entirely wrapped by the thermoplastic matrix. Using this method, a form- and material fitted structure is generated by process integration. Air locking defects can be suppressed by the rotational tool motion through an improved local contact pressure. Applying a rotational motion influences the flow direction and fibre orientation in positive manner. An extensive material characterization has been carried out. In order to describe the flow behaviour of the polymer component, viscosity data is needed. Therefore, experimental investigations are carried out and provided for the FE simulation.",
keywords = "Finite element method, Hybrid material, Production technology, Sheet metal",
author = "Behrens, {B. A.} and A. Chugreev and J. Moritz and F. Bohne and H. Schulze",
year = "2018",
language = "English",
isbn = "9781510896932",
booktitle = "ECCM 2018 - 18th European Conference on Composite Materials",
note = "18th European Conference on Composite Materials, ECCM 2018 ; Conference date: 24-06-2018 Through 28-06-2018",
}