Intrinsic production of hybrid components utilizing a modified RTM-process

研究项目的主要目标是将已开发的固有制造工艺的概念从第一个资助期(FP 1)转移到复杂的结构、实际加载条件和大规模生产。为了确保预制件在高温下完全浸渍并缩短循环次数，必须增加注射压力。重要的是实现同质的接口层。这一层作为荷载传递元件，主要影响混合结构的整体性能。此外，金属和玻璃钢一侧的不同加热，在第一次成形过程中为减少残余应力而开发，将转移到复杂的几何形状。此外，还将研究一种自密封工具概念，它可以补偿部件公差，并允许取代易磨损的硅密封。最后，FP 1中采用的张开式螺柱的概念将扩展到三维结构。为此，必须开发一种灵活的锚定机构，必须确保减少干涉轮廓，必须选择合适的表面处理，并必须测试附加的刀具运动学。在材料科学领域，在FP 1中使用激光构造来实现改善附着力的3D几何形状是不可行的。为了形成先前结构的金属薄板，必须开发一种抗变形的结构。此外，激光的非正交性照射会导致不均匀的结构，这必须避免。此外，在FP 1中发现了激光器和加载方向之间的依赖关系，因此应该研究负载调整结构。三维混合结构的循环和碰撞载荷以及老化，应该在FP 2中进行检查，导致复杂的失效机制。因此，必须开发合适的测试方法。这些被用来表征材料和确定用于模拟的特征值。工艺开发基于对工艺步骤的描述，通过有实验基础的建模和模拟。为了宏观地确定复杂混杂构件成型充型过程中的流动前沿，将固化行为和流动行为耦合起来。实际加载条件对构件设计的影响是非常重要的。这种影响将通过模拟母体的老化来描述，而不是通过混合组件的老化来描述。为了模拟混杂结构在老化影响下的碰撞行为，发展了均匀化方法。此外，老化还与失效机制相耦合。

The main objective of the research project is to transfer the developed concept of an intrinsic manufacturing process from the first funding period (FP 1) to complex structures, real loading conditions and large-scale production. An internally reinforced B-pillar as well as an externally reinforced transmission tunnel are considered as demonstrators.In order to ensure a complete impregnation of the preform at elevated temperatures and to reduce the cycle times, the injection pressure has to be increased. Of great importance is the realization of a homogeneous interface layer. This layer acts as the load transmission element and thus mainly influences the overall function of the hybrid structures. Furthermore, the different heating of the metal and FRP side, developed during the first FP to reduce residual stresses, will be transferred to complex geometries. In addition, a self-sealing tool concept, which compensates for component tolerances and allows to replace the liable to wear silicon sealing will be studied. Finally, the splay stud concept, which is pursued in FP 1, is to be extended to 3D structures. For this purpose, a flexible anchoring mechanism has to be developed, a reduction of the interference contour has to be ensured, a suitable surface pretreatment has to be selected and additional tool kinematics have to be tested.In the field of materials science the laser structuring used in the FP 1 to achieve improved adhesion is not feasible for 3D geometries. For the forming of previously structured metal sheets a deformation-resistant structuring has to be developed. Moreover, non-orthogonal irradiation of the laser beam results in uneven structuring, which has to be avoided. Furthermore, in FP 1 a dependency between the laser and the loading direction was found, so that a load-adjusted structuring should be investigated. The cyclic and crash loadings and aging of the 3D hybrid structures, that should be examined in FP 2, cause complex failure mechanisms. Therefore suitable test methods have to be developed. Those are used to characterize the materials and to identify characteristic values for the simulation.The process development is based on the description of the process steps by experimentally well-founded modeling and simulation. For the macroscopic determination of the flow front during the form filling of complex hybrid components a coupling of curing and flow behavior is aimed. The influence of real loading conditions is very important for the component design. This influence will be described by the simulation of the aging of the matrix instead of the aging of the hybrid component. In order to simulate the crash behavior of the hybrid structure under the influence of aging, homogenization methods are developed. In addition the aging is coupled with the failure mechanisms.