A novel method for manufacturing of hybrid structures made of metal and fiber reinforced plastics using a multidirectional forming process

verfasst von: Johannes Holt, Bernd-Arno Behrens, Johanna Uhe, Hendrik Wester
Abstract: Hybrid materials are increasingly used in lightweight construction. The combination of metallic materials with fiber-reinforced plastics (FRP) can reduce weight and improve the mechanical properties of a component. FRP are known for their lightweight and corrosion resistance, while metals show high strengths and stiffnesses. In order to combine the advantages of both materials, it is possible to reinforce highly stressed segments of a metallic component with FRP. A novel method for manufacturing such hybrid metal-FRP composite structures using a multidirectional forming process is investigated. Thereby, a glass mat reinforced thermoplastic (GMT), consisting of a polypropylene matrix with 40% glass fiber reinforcement, is compression moulded on specific segments of a metallic component by means of a controlled multidirectional die. For this, finite element (FE) simulations are required to design a forming process close to an industrial application. In order to conduct such a numerical study of the material flow during forming, a precise characterization of the GMT is necessary. Therefore, isothermal compression tests were conducted using a parallel-plate rheometer at different temperatures ranging from 180 °C to 220 °C and varying squeeze rates from 0.05 mm/s to 2 mm/s. The experimental data is used to fit a material model for the FE simulations. To verify the material model for further simulations in the project, the compression process is simulated in ABAQUS using a Coupled Eulerian-Lagrange approach and the results are compared with the experimental data.
Organisationseinheit(en): Institut für Umformtechnik und Umformmaschinen
Typ: Aufsatz in Konferenzband
Seiten: 456-460
Anzahl der Seiten: 5
Publikationsdatum: 26.06.2024
Publikationsstatus: Veröffentlicht
Peer-reviewed: Ja
ASJC Scopus Sachgebiete: Werkstoffmechanik, Metalle und Legierungen, Oberflächen, Beschichtungen und Folien
Elektronische Version(en): https://doi.org/10.37904/metal.2024.4904 (Zugang: Geschlossen)
: Details im Forschungsportal „Research@Leibniz University“

BibTeX

@inproceedings{e5d79782e98847f3b508c27490edc8e6,
title = "A novel method for manufacturing of hybrid structures made of metal and fiber reinforced plastics using a multidirectional forming process",
abstract = "Hybrid materials are increasingly used in lightweight construction. The combination of metallic materials with fiber-reinforced plastics (FRP) can reduce weight and improve the mechanical properties of a component. FRP are known for their lightweight and corrosion resistance, while metals show high strengths and stiffnesses. In order to combine the advantages of both materials, it is possible to reinforce highly stressed segments of a metallic component with FRP. A novel method for manufacturing such hybrid metal-FRP composite structures using a multidirectional forming process is investigated. Thereby, a glass mat reinforced thermoplastic (GMT), consisting of a polypropylene matrix with 40% glass fiber reinforcement, is compression moulded on specific segments of a metallic component by means of a controlled multidirectional die. For this, finite element (FE) simulations are required to design a forming process close to an industrial application. In order to conduct such a numerical study of the material flow during forming, a precise characterization of the GMT is necessary. Therefore, isothermal compression tests were conducted using a parallel-plate rheometer at different temperatures ranging from 180 °C to 220 °C and varying squeeze rates from 0.05 mm/s to 2 mm/s. The experimental data is used to fit a material model for the FE simulations. To verify the material model for further simulations in the project, the compression process is simulated in ABAQUS using a Coupled Eulerian-Lagrange approach and the results are compared with the experimental data.",
keywords = "Composite materials, glass mat reinforced thermoplastic, multidirectional forming process, numerical simulation",
author = "Johannes Holt and Bernd-Arno Behrens and Johanna Uhe and Hendrik Wester",
note = "Publisher Copyright: {\textcopyright} 2024 Tanger Ltd., Ostrava.",
year = "2024",
month = jun,
day = "26",
doi = "10.37904/metal.2024.4904",
language = "English",
series = "Metal",
pages = "456--460",
booktitle = "METAL Conference Proeedings",
}