Process optimization of induction welding of continuous carbon fiber reinforced thermoplastics with the aid of process simulation

该项目的目的是优化连续碳纤维增强热塑性复合材料，特别是有机板材的感应焊接工艺。层压板和纺织品参数对感应加热行为影响的基本原理，优化表面冷却的选择和验证，以及连接区域压力区域的温度相关计算已经成功地进行了调查和记录在项目中（删除了符号）。这一持续提案的重点是将这些发现整合到感应焊接过程的扩展整体模型中，从而优化步骤和建立结合强度模型。在此基础上，将建立一个用于静态感应加热计算的仿真模型。为了模拟纺织品和层压参数的影响，目标是通过推导电导率和累积投影接触面积之间的相关性来补充。随后，将这种静态模拟转化为动态模拟（连续过程），并实现所开发的表面冷却（喷雾冷却系统）。连接强度的理论确定是基于熟悉的结合度方法。此外，一种由弹性体制成的固结辊正在开发中，以增加过程的稳健性，并在连接区实现更大更均匀的压力分布。通过焊接机器人的焊接试验和显微拉伸剪切试验对仿真结果进行了验证。

The aim of the project is to optimise the induction welding process of continuous carbon fiber reinforced thermoplastic composites, especially organic sheets. The fundamental principles of the influences of the laminate and textile parameters on the inductive heating behavior, the selection and verification of an optimised surface cooling as well as the temperature-dependent calculation of the pressure zone in the joining area have already been successfully investigated and documented in the project(sign removed). Focus of this continuing proposal is the consolidation of these findings into an extended overall model for the induction welding process, resulting optimisation steps and the modeling of the bonding strength. Based on the findings, a simulation model for the calculation of static inductive heating will be developed. In order to simulate the influence of the textile and laminate parameters, the objective is supplemented by the derivation of a correlation between electrical conductivity and cumulated projected contact area. Subsequently, this static simulation is converted into a dynamic simulation (continuous process) and the developed surface cooling (spray cooling system) is implemented. The theoretical determination of the joining strength is based on the conversant approach of the Degree of Bonding. In addition, a consolidation roller made of elastomer is being developed to increase the process robustness and to achieve a larger and more homogeneous pressure distribution in the joining zone. The verification of the simulation results is carried out by welding tests on the welding robot and tensile shear test with micrograph analysis.