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.

连接区域的设计和尺寸通常代表成功开发用于汽车行业，机器和工厂制造的混合轻量级组件的关键因素。在轻量级设计的大多数领域，金属负载介绍元件作为连续纤维增强塑料的可靠和高效连接技术被广泛接受。迄今为止，此类插入物必须在组件制造过程中付出很大的努力，或者需要额外的过程步骤进行集成。通过新型的自动化过程插入物，可以在使用温暖的形成技术的组件制造过程中集成。在整个过程中，加固纤维通过锥形销重新定向，从而产生复杂的材料结构，其纤维取向和纤维体积分数有局部变化。在此类关节的设计过程中，必须认为负载引入区域中的材料结构能够对承重行为进行可靠的描述。但是，连续的多尺度处理和结构仿真方法尚不可用，严格的实验表征将需要不适当的测试工作。因此，在该项目中，应开发一种实验辅助的数值表征方法，用于加入加入区域，从而有效地使用嵌入式插入式插入式插入式插入式插入式的Zone的系统设计。因此，对于每个插入设计，仅制造一个代表性的加入区，然后通过计算机断层扫描来分析以确定微观上的局部纤维取向和纤维含量。基于此数据，确定局部材料属性并将其实现为FE模型。使用此模型，现在可以为所有与设计相关的负载方案对联接区域的变形和损坏行为进行数值分析。然后，这些结果应用于为负载应用程序元素，会计材料结构和过程特定方面提出系统设计过程。