Simulation-assisted development of material-, load- and process-specific inserts for thermoplastic composites

仿真辅助开发热塑性复合材料的材料、负载和工艺特定嵌件

• 批准号: 408132410
• 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: Research Grants
• 财政年份: 2018
• 资助国家: 德国
• 起止时间: 2017-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/408132410?language=en
• 关键词: Simulation; assisted; development; material; load

The design and dimensioning of joining zones often represents a key factor for the successful development of hybrid lightweight components for automotive industry, machine and plant manufacture. The application of metallic load introduction elements as a reliable and efficient joining technique for continuous fibre reinforced plastics is widely accepted in most areas of lightweight design. To date, such inserts either have to be embedded with high effort during component manufacturing or need an additional process step for integration. By means of a novel automated process inserts now can be integrated during component manufacturing utilising warm forming technology. Throughout this process, the reinforcing fibres are reoriented by a tapered pin, resulting in a complex material structure with locally varying fibre orientations and fibre volume fractions. In the design process of such joints, the material structure in the load introduction zone has to be considered to enable a reliable description of the load-bearing behaviour. However, continuous multi-scale processing and structural simulation methods are not available yet, and a strictly experimental characterisation would require an inappropriate testing effort.Hence, within this project an experimentally-assisted numerical characterisation method for warm formed joining zones shall be developed, enabling an efficient systematic design of load application zones with embedded inserts. Thereby, for each insert design only one representative joining zone is manufactured and then analysed by computed tomography to determine local fibre orientations and fibre contents on microscale. Based on this data the local material properties are determined and implemented into an FE model. With this model, the deformation and damage behaviour of the joining zone can now be numerically analysed for all design-relevant loading scenarios. These results shall then be used to propose a systematic design process for load application elements, accounting material structure and process specific aspects.

连接区的设计和尺寸通常是汽车工业、机械和工厂制造中混合轻量化部件成功开发的关键因素。金属载荷引入元件作为一种可靠、高效的连续纤维增强塑料连接技术，在大多数轻量化设计领域得到了广泛的应用。迄今为止，这样的插入件要么必须在组件制造过程中花费大量精力嵌入，要么需要额外的工艺步骤进行集成。通过一种新的自动化工艺，现在可以在部件制造过程中利用热成形技术集成刀片。在整个过程中，增强纤维通过锥形针重新定向，从而形成具有局部不同纤维取向和纤维体积分数的复杂材料结构。在此类接头的设计过程中，必须考虑载荷引入区的材料结构，以便可靠地描述其承载性能。然而，连续的多尺度处理和结构模拟方法尚不可用，严格的实验表征将需要不适当的测试工作。因此，在本项目中，应开发一种热成形连接区域的实验辅助数值表征方法，从而能够有效地系统设计具有嵌入式嵌件的负载应用区域。因此，对于每个插入设计，只制造一个具有代表性的连接区域，然后通过计算机断层扫描分析，以确定局部纤维取向和微尺度上的纤维含量。基于这些数据，确定了材料的局部特性，并将其实现为有限元模型。有了这个模型，连接区域的变形和破坏行为现在可以在所有设计相关的加载情况下进行数值分析。然后，这些结果将用于提出一个系统的设计过程，用于负载应用元件，会计材料结构和工艺具体方面。