Continuous analysis of variations during the design of endless-fiber reinforced composite structures assemblies

在产品设计中考虑变型及其功能约束是公差管理的一项重要任务。纤维增强塑料材料(FRP)因其高度的轻量化潜力而越来越多地应用于重量敏感的应用中，但由于其设计参数较多，增加了这项任务的复杂性。由于层压板设计参数的变化，各个部件的几何变化和残余应力也会传递到装配中，从而传递到最终产品中。由于装配过程，在装配过程中可能会在装配中产生额外的残余应力，这对装配的可承受载荷有影响。在最坏的情况下，这可能会导致偏离的组件过早失效。以往的方法考虑了装配过程中的残余应力，但没有考虑层合板设计参数的变化。这些方法大多源于制造工程，因此没有考虑后续产品的使用。为了克服这一点，并能够在设计阶段考虑制造对结构性能的影响，必须开发一种包括连续虚拟过程链的新方法。该研究项目的目的是提供一种方法，用于持续考虑从复合材料组件的设计阶段到使用阶段的层合板设计参数的变化及其影响。这应使产品开发人员能够在设计玻璃钢结构时发现潜在问题，并采取适当的有针对性的对策。

The consideration of variations and their functional restriction during the design of a product is an important task of tolerance management. Fibre reinforced plastic materials (FRP), which are increasingly used in weight-sensitive applications due to their high lightweight potential, increase the complexity of this task due to their high number of design parameters. Geometric variations and residual stresses of individual components, which result from variations in the laminate design parameters, also transfer into the assembly and thus the final product. Additional residual stresses can occur in the assembly due to the assembly process, which have an impact on the supportable loads of the assembly. In the worst case, this can lead to premature failure of the deviated assembly. Previous approaches consider residual stresses during assembly, but do not take into account the variations of the laminate design parameters. Most of these approaches originate from manufacturing engineering and therefore do not take into account the subsequent product use. To overcome this, and be able to consider the effects of the manufacturing on the structural performance during the design phase, a new method including a continuous virtual process chain has to be developed. The aim of the proposed research project is to provide a method for the continuous consideration of variations of laminate design parameters and their effects from the design phase up to the use phase of the composite assembly. This should enable product developers to identify potential problems during the design of the FRP structure and to take appropriate targeted countermeasures.