Blanking of fibre reinforced plastics. Manufacturing technology and numerical modelling

与传统建筑材料相比，碳纤维增强塑料（CFRP）具有较高的强度密度比。碳纤维增强塑料的这种材料特性为在基于材料的轻量化设计的竞争中制造重量优化部件提供了巨大的潜力。预计CFRP组件将用于汽车工业的大批量生产。碳纤维增强塑料构件通常采用近净形制造。为了进一步使用这些CFRP组件，需要对功能元件的产生进行切边或穿孔。适合大批量生产的一种具有潜在经济效益的制造技术是冲裁。CFRP落料不属于目前的技术水平，因此尚未对落料过程中的因果关系进行研究。本建议的目的是发展一种分析经验模型，通过这种模型，可以充分解释下料过程中材料行为和最终工件质量之间的主要因果关系。对切割带物理机制的理解是研究的重点。这些机制基本上是由CFRP复合材料的变形、损伤和最终破坏决定的。通过对基本工艺的了解，可以通过以结果为导向的工艺设计，实现具有高工件质量的CFRP落料。解释模型的开发是通过IFAM和WZL的合作来实现的。IFAM进行材料表征以及微观驱动材料模型的制定和数值实现，该模型能够真实再现CFRP在落料过程中的分离。WYL负责对CFRP落料进行系统的实验研究，识别工艺参数与工艺结果之间的重要因果关系。这些见解将在材料模型的开发过程中被考虑。此外，WZL使用IFAM开发和实施的材料模型对CFRP冲裁进行了数值分析。最后，根据所得结果综合CFRP在冲裁过程中分离的解释模型。

Carbon fibre reinforced plastics (CFRP) demonstrate a high strength to density ratio as compared with the conventional construction materials. This material property of CFRP defines a high potential for the manufacturing of the weight-optimized components in the contest of material based lightweight design. It is expected that CFRP components will be used in high-volume production of the automotive industry. The CFRP components are often manufactured near-net-shape. For the further usage of these CFRP components trimming or piercing for the generation of the functional elements is required. One potentially economically efficient manufacturing technology suitable for the high-volume production is blanking. CFRP blanking does not belong to the state of the art so that the cause and effect relationships during the blanking process are not yet researched.The aim of this proposal is the development of an analytical-empirical model by which means principal cause and effect relationships between the material behavior and the resulting workpiece quality in blanking process can be adequately explained. Understanding of the physical mechanisms in the cutting zone lies in in the focus of the study. These mechanisms are essentially determined by the deformation, resulting damage and ultimately failure of the CFRP compound. The acquired understanding of the basic processes enables subsequently the realization of CFRP blanking with a high workpiece quality through the result-oriented process design.The development of the explanation model is realized through the cooperation of IFAM and WZL. IFAM carries out the material characterization as well the formulation and numerical implementation of a microscopically motivated material model that is capable of realistic reproduction of the CFRP separation in blanking process. The WYL is responsible for the systematic experimental investigation of the CFRP blanking and identification of the significant cause and effect relationships between the process parameter and the process results. These insights will be considered during the development of the material model. Furthermore, the WZL carries out a numerical analysis of the CFRP blanking using the material model developed and implemented by IFAM. Finally, the explanation model for the CFRP separation in blanking process will be synthesized from the obtained findings.