Simulation-aided development and qualification of a novel Thermoclinch joining technology for multi-material design with textile-reinforced thermoplastic composites

用于纺织增强热塑性复合材料多材料设计的新型 Thermoclinch 连接技术的模拟辅助开发和鉴定

• 批准号: 227385749
• 负责人: Professor Dr.-Ing. Maik Gude
• 金额: --
• 依托单位: Institut für Leichtbau und Kunststofftechnik
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2012
• 资助国家: 德国
• 起止时间: 2011-12-31 至 2017-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/227385749?language=en
• 关键词: Simulation; aided; development; qualification; novel

Aim of the proposed project is the simulation-aided development of a novel forming-based joining technology for metal-plastic hybrid structures with thermoplastic composites. Within the devised joining method thermoclinching, the locally heated and plasticised composite is moulded through an opening in the metallic part and spread to an undercut with defined fibre architecture. With the aim of raising process capabilities and reducing cycle times, the thermoclinching technology is further developed by integrating the pre-processed steps of cutting and heating into the actual joining process.Therefore, adapted joining devices, forming tools and process parameters are developed for the advanced thermo-mechanical process, which is characterised by large plastic deformations of the textile reinforced thermoplastic.The fundamental theoretical, technological and experimental investigations are performed on the example of the material configuration glass-fibre reinforcedpolypropylene (GF/PP) and steel sheet metal. Based on this, alternative material combinations with brittle carbon fibre reinforcement and low-viscous matrix systems like polyamide are evaluated for the inline-thermoclinching process.The realistic prediction of the deformation and failure behavior in thermoclinching joints is based on a numerical multiscale process simulation strategy with coupled process and structural models. The simulation tool is extended to integrate default laminate structures and material combinations for the structural analysis of the joints and the numerical prediction of joint properties.For the detailed analysis of the thermoclinching joints, selected joint configurations will be manufactured and evaluated on the macroscopic level by characterising the joint shape and on the microscopic level by evaluating the deformation-induced local fibre alignments. For the extensive structure determination of the joints, the computed tomography is applied and additionally used to validate process simulations, especially with respect to the resulting joint characteristic. Furthermore, in-situ-computed tomography is used for an in-depth understanding of the successively damage behavior under tension-shear and peel loading.The numerical and experimental evaluations of the anticipated complex interaction between process-specific influences and joint properties are performed using standardized test methods for single-lap joints (tension-shear and peel load). On that basis, quality assurance methods are derived for producing hybrid joints with reproducible joint properties. Based on a comprehensive assessment of the novel connection method, material specific design rules for a load adapted design of structural joints are deduced. In addition, constructive design guidelines for inline-thermoclinch-installations are worked out.

该项目的目的是模拟辅助开发一种新的基于成形的金属-塑料混杂结构与热塑性复合材料的连接技术。在设计的连接方法热固结中，局部加热和塑化的复合材料通过金属部分的开口模制，并扩散到具有定义的纤维结构的下切。为了提高加工能力和缩短生产周期，将切割和加热的前处理步骤融入到实际的连接过程中，进一步发展了热固接技术。为此，针对纺织增强热塑性塑料塑性变形大的先进热机械工艺，开发了适用的连接装置、成型工具和工艺参数。以玻璃纤维增强聚丙烯(GF/PP)和钢板金属为例，进行了基本的理论、工艺和实验研究。在此基础上，评估了脆性碳纤维增强和聚酰胺等低粘性基质体系的替代材料组合在内嵌热固接过程中的作用。基于过程和结构耦合模型的多尺度数值模拟策略，对热固接接头的变形和破坏行为进行了现实预测。该模拟工具被扩展为集成默认的层合板结构和材料组合，用于接头的结构分析和接头性能的数值预测；对于热固接接头的详细分析，将通过表征接头形状在宏观层面上制造和评估选定的接头结构，并在微观层面上通过评估变形诱导的局部纤维对齐来评估所选择的接头结构。为了广泛确定接头的结构，应用了计算机断层成像，并另外用于验证工艺模拟，特别是关于所产生的接头特性。此外，现场计算机层析成像用于深入了解拉伸剪切和剥离载荷下的连续损伤行为，使用标准化的单搭接接头(拉伸剪切和剥离载荷)试验方法，对工艺特定的影响和接头性能之间预期的复杂交互作用进行了数值和实验评估。在此基础上，提出了生产具有可重复接头性能的混杂接头的质量保证方法。在对这种新型连接方法进行综合评价的基础上，推导出了适用于结构节点荷载适应设计的具体材料设计准则。此外，还制定了直列式热扣装置的建设性设计指南。