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.

拟议项目的目的是与热塑性复合材料的金属塑料混合结构的新型基于形成的连接技术的模拟开发。在设计的连接方法中，局部加热和塑料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底切。旨在提高过程能力并减少周期时间，通过将切割和供暖的预先处理和供暖的步骤进一步开发到进一步的发展中，因此，为高级机械测试而开发了适应性的连接设备，形成工具和工艺参数，由高级机械过程开发，由大型塑料构成构造的构造构成的构造，并构成了构造的构造，并构成了构造的构造，并具有构造的构造，并构成了构造的构造。以材料构型玻璃纤维增​​强丙烯（GF/PP）和钢板金属的示例进行。基于此，评估具有脆性碳纤维增强的替代材料组合和低粘性基质系统（如多酰胺）进行内联 - 心理链接过程。在热网链接接头中对变形和故障行为的现实预测是基于数值多架过程模拟和结构模型的数值多轴过程模拟策略。将模拟工具扩展到整合默认的层压结构和材料组合，以进行关节的结构分析和关节性质的数值预测。对于热链接接头的详细分析，将通过对近距离的局部层面来对其进行较大层次的层次制造和评估，并通过评估近距离级别的水平来进行评估。对于关节的广泛结构确定，计算出的断层扫描被应用并另外用于验证过程模拟，尤其是在所得的关节特征方面。此外，原位计算的断层扫描用于深入了解张力剪切和果皮负荷下的依次损害行为。对过程特异性影响和关节性能之间预期的复杂相互作用的数值和实验评估是使用标准化测试方法（张力壳和果皮负载）进行的。在此基础上，得出了用于生产具有可重复性关节特性的混合关节的质量保证方法。基于对新型连接方法的全面评估，推导了针对结构关节负载设计的材料特定设计规则。此外，还制定了有关内联 - 塞林加安装的建设性设计指南。