Investigation of the transferability of the fatigue behaviour of fibre-reinforced plastics from coupon samples to optimised higher-level components for the development of a design guideline

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Effective and reliable product development methods for fibre reinforced plastic composites (FRP) allow a high degree of exploitation of lightweight design potential, as safety factors can be reduced due to a better understanding of the interactions and a precise knowledge of the distribution of influencing factors. In the present research project, a method for the consideration of the fatigue behaviour of FRP in the design of high-level components is to be conceived, implemented and evaluated on two examples, which on the one hand considers the special features of optimised layer structures and on the other hand the influence of material and structural uncertainties on the fatigue behaviour. The method considers the scatter of the influencing factors and enables the product developer to create robust designs. It is based on detailed experimental investigations on different levels of the test pyramid, from which conclusions are drawn about suitable design limits for the determination of the FRP fatigue behaviour, and also quantifies occurring distributions of individual influencing parameters. Starting with coupon samples, the results are successively transferred to the semi-finished product level, considering any uncertainties that may occur. A further focus lies on the optimisation of the force introduction points. After comprehensive evaluation, the findings will be transferred to software tools, which should increase the acceptance of lightweight FKV construction methods among users. Finally, two different demonstrator concepts will be derived, manufactured and tested jointly by the two applicants based on the developed method and knowledge base. Based on these results, the method will be evaluated and further potentials will be shown.