The paper describes a novel testing method for mechanical joints between fibre-reinforced plastics and metals. As an example, the paper discusses a connection between a continuous carbon-fibre-reinforced plastic and aluminium via a flow drill screw. The failure load of the joints under different loading angles was tested with the help of a modified KS-II testing facility. A detailed analysis of the damage and failure behaviour of the connection was performed by means of optical recordings and micrographs. The results indicate that the tested material combination has nearly the same failure load at different loading angles with various failure mechanisms. The experimental results can be used to devise new failure criteria for these connections and to detect limit values for the design process.
Crash absorbers made of fibre‐reinforced plastics becoming more and more popular to reduce the mass in the front section of cars. Various research projects analysed the high specific energy absorption and the stable crushing behaviour of this material, however without examining the connection to other car body components. This paper focuses on the connection of the crash absorbers to the bumper system, particularly regarding to the crushing behaviour. An initial step focused on the development of a crash absorber made of carbon‐fibre‐reinforced plastic, which shows similar energy absorption compared to absorbers made of aluminium. A following step investigated various connection concepts using a drop tower. These first connection concepts resulted in unstable crushing behaviour. The finite element simulation of the tests delivered additional information about the reasons for the insufficient crushing behaviour. Subsequently, a simulation of various connection concepts turned out suitable connection concepts. A final drop tower test investigated the best connection concept. The developed connection system shows similar to the unmodified crash absorber stable crushing behaviour.
This publication describes novel experimental and numerical investigations on the punching failure of carbon fiber-reinforced plastics. This kind of failure is relevant in joining processes as well as a characteristic failure type of mechanical fasteners between metals and carbon fiber-reinforced plastics like rivets or screws. So far, there is a lack of a precise phenomenological description of this failure mode. For this reason, this paper focuses on the experimental analysis of the damage and failure mechanism. As a result, the experiments show a failure evolution without any shearing of the fibers. This provides the basis for the accompanying simulation using the finite element method. Subsequently, the simulation of the experiments demonstrates that a modeling of a punching failure is possible by a combination of known fiber, inter-fiber and delamination failure criteria without extensions.
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