Investigation of the Process Limits for Hybrid Parts Made of Fiber-Reinforced Thermoplastics and Metallic Sheets Produced with a Two-Stage Isothermal Forming and Consolidating Tool

authored by: J. Wehmeyer, T. Fünfkirchler, S. Hübner, C. Schumann, A. Raatz, B. A. Behrens
Abstract: Multi-material structures are promising in the automotive industry for achieving lightweight design body construction and functionalization due to their favorable mechanical properties and low structural weight. These structures typically combine metal and plastic materials to create final components with enhanced properties compared to mono-material structures. The focus of this paper lays on the creation of a manufacturing cell that combines joint forming and heat-assisted press joining techniques to produce components made from steels and continuous fiber-reinforced thermo-plastics in the form of unidirectional carbon-fiber tapes. To improve production efficiency and reduce costs, a manufacturing cell was created and tested, which utilized two robots for automated handling and an isothermal, two-stage forming tool concept to shorten cycle times. The resulting composite components were tested for mechanical performance. Compared to pure steel components, all composite components exhibited a higher specific load capacity. Cycle times in well under 60 s were achieved. The new manufacturing cell led to a significant reduction in process time compared to variothermal tool concepts.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Institute for Assembly Technology and Robotics
Type: Contribution to book/anthology
Pages: 660-669
No. of pages: 10
Publication date: 18.11.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Industrial and Manufacturing Engineering, Economics, Econometrics and Finance (miscellaneous), Safety, Risk, Reliability and Quality
Electronic version(s): https://doi.org/10.1007/978-3-031-47394-4_64 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inbook{cb01da34db57421a91f417fbc0633f01,
title = "Investigation of the Process Limits for Hybrid Parts Made of Fiber-Reinforced Thermoplastics and Metallic Sheets Produced with a Two-Stage Isothermal Forming and Consolidating Tool",
abstract = "Multi-material structures are promising in the automotive industry for achieving lightweight design body construction and functionalization due to their favorable mechanical properties and low structural weight. These structures typically combine metal and plastic materials to create final components with enhanced properties compared to mono-material structures. The focus of this paper lays on the creation of a manufacturing cell that combines joint forming and heat-assisted press joining techniques to produce components made from steels and continuous fiber-reinforced thermo-plastics in the form of unidirectional carbon-fiber tapes. To improve production efficiency and reduce costs, a manufacturing cell was created and tested, which utilized two robots for automated handling and an isothermal, two-stage forming tool concept to shorten cycle times. The resulting composite components were tested for mechanical performance. Compared to pure steel components, all composite components exhibited a higher specific load capacity. Cycle times in well under 60 s were achieved. The new manufacturing cell led to a significant reduction in process time compared to variothermal tool concepts.",
keywords = "Advanced materials, lightweight structures, multi-material concepts/solutions",
author = "J. Wehmeyer and T. F{\"u}nfkirchler and S. H{\"u}bner and C. Schumann and A. Raatz and Behrens, {B. A.}",
note = "Funding Information: Acknowledgements. The authors thank the Industrial Collaborative Research (IGF) and the European Research Association for Sheet Metal Working (EFB) for the financial support of the research project “Economical production of load-compliant FRP/metal composites“ (IGF-Code: 19603N). ",
year = "2023",
month = nov,
day = "18",
doi = "10.1007/978-3-031-47394-4_64",
language = "English",
isbn = "978-3-031-47393-7",
series = "Lecture Notes in Production Engineering",
publisher = "Springer Nature",
pages = "660--669",
booktitle = "Production at the Leading Edge of Technology",
address = "United States",
}