Design strategies and production processes of strength-optimised lightweight structures made of composites with variableaxial fibre architecture (OptiTex)

纺织品增强塑料是一个年轻的材料家族，有望成为轻量化解决方案的巨大潜力。这里，纺织纤维布局可以适于类似于自然界中的构造的复杂的局部变化的力流取向。也是针对负载条件专门选择的基质材料主要用于保护和稳定织物加固以及产生均匀的力分布。对于各种织物增强复合材料结构，强度要求占主导地位的设计过程，然而，这是比刚度驱动的设计要求更高。为了充分利用新型纺织增强材料组的高强度潜力，必须提供适当的纺织和塑料技术，以及基于物理失效标准的材料导向分析和优化策略，并考虑纺织工艺特定制造参数的限制。为此，在材料构造、计算和制造的工艺步骤之间建立非常紧密的联系是绝对必要的，以便开发具有可变轴向织物增强的强度优化复合材料。因此，在这个合作研究项目中，一方面是建模，模拟和优化学科之间的跨学科合作，另一方面是具有给定纤维布局的纺织品预成型件的制造及其与高纤维体积含量的合并。因此，目前计划的合作项目明显不同于仿生学领域的研究项目，后者主要涉及刚度优化。在拟议的研究项目中，将研究通过定制纤维位置（TFP）和部分可调经向纤维位置的多轴向无卷曲织物（MAG-KV）技术制造的薄壁和厚壁复合材料结构。它们都允许可变轴向纤维增强布局，并有资格进行大规模生产。该研究项目的第一阶段包括设计和验证特定的薄壁示范，以实现最大强度极限使用开发的面向过程的模拟和优化方法。在此背景下，有关纺织品为导向的金属轴承领域的设计方面也将得到澄清。通过研究平面和空间形状的薄壁试样开发的基于技术的方法将通过拉伸、弯曲和扭转载荷的断裂试验进行实验验证。在此基础上，在研究项目的第二阶段，将通过分析厚壁复合材料来增加演示和设计的复杂性。

Textile-reinforced plastics, a still young family of materials, promise a substantially high potential for lightweight solutions. Here, the textile fibre layout can be adapted for complex locally changing force flow orientations similarly to constructions in nature. The matrix material, which is also specifically chosen for the load conditions, serves mainly the protection and stabilisation of the textile reinforcement as well as the generation of a uniform force distribution. For a variety of textile reinforced composite structures the strength requirements dominate the design process, which, however, is much more demanding than stiffness driven designing. To fully exploit the high strength potential of the new textile reinforced material group adequate textile and plastic technologies have to be provided as well as material-oriented analysis and optimisation strategies with physically based failure criteria considering the limits of the specific manufacturing parameters of the textile process. For this purpose, a very close link between the process steps material construction, calculation and manufacturing is absolutely necessary in order to develop strength-optimised composites with variableaxial textile reinforcement. Thus, within this collaborative research project, an intensive interdisciplinary cooperation between the disciplines modelling, simulation and optimisation, on the one hand, as well as manufacturing of textile preforms with a given fibre layout and its consolidation with high fibre volume contents on the other hand, is intended. Hence, the present planned collaborative project differs clearly from research projects in the field of bionics, which mainly deals with stiffness optimisation.Within the proposed research project, both thin-walled and thick-walled composite structures manufactured by the technologies Tailored Fibre Placement (TFP) and multi-axial non-crimp fabric with partial adjustable warp fibre placement (MAG-KV) will be investigated. Both of them allow a variableaxial fibre reinforcement layout and qualify for large-scale production. The first period of the research project comprises designing and validation of specific thin-walled demonstrators to achieve the maximum strength limits using the developed process-oriented simulation and optimisation methods. In this context, aspects about textile-oriented designing of metallic bearing areas will be clarified too. Technology-based methods developed by investigating plane and spatially shaped thin-walled specimens will be experimentally validated by fracture tests with tension, bending and torsion loads. Based on this knowledge the demonstrator and design complexity will be increased by analyzing thick-walled composites within the second period of the research project.