Numerical Modelling of Bond Strength in Overmoulded Thermoplastic Composites

authored by: Bernd Arno Behrens, Klaus Dröder, Kai Brunotte, Hendrik Wester, André Hürkamp, Tim Ossowski, Ralf Lorenz
Abstract: Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly func-tionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of over-moulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Open Hybrid LabFactory E.V.
Technische Universität Braunschweig
Type: Article
Journal: Journal of Composites Science
Volume: 5
Publication date: 07.2021
Publication status: Unpublished
Peer reviewed: Yes
ASJC Scopus subject areas: Ceramics and Composites, Engineering (miscellaneous)
Electronic version(s): https://doi.org/10.3390/jcs5070164 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{ac7904055fa44df9928ee726aee55031,
title = "Numerical Modelling of Bond Strength in Overmoulded Thermoplastic Composites",
abstract = "Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly func-tionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of over-moulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.",
keywords = "Bond strength, Injection moulding, Numerical modelling, Overmoulding, Thermoforming, Thermoplastic composites",
author = "Behrens, {Bernd Arno} and Klaus Dr{\"o}der and Kai Brunotte and Hendrik Wester and Andr{\'e} H{\"u}rkamp and Tim Ossowski and Ralf Lorenz",
note = "Funding Information: Funding: The IGF-Project “Integrated process simulation of thermoforming and injection moulding” of the European Research Association for Sheet Metal Working (EFB e.V.) was funded by the Federal Ministry of Economics and Energy (BMWi) under the funding number 20524N of the German Federation of Industrial Research Associations (AiF) on the basis of a decision by the German Bundestag. The authors are thankful for this financial support. ",
year = "2021",
month = jul,
doi = "10.3390/jcs5070164",
language = "English",
volume = "5",
journal = "Journal of Composites Science",
issn = "2504-477X",
publisher = "MDPI AG",
number = "7",
}