Automated Stamp Forming of Continuous Fiber Reinforced Thermoplastics for Complex Shell Geometries

Behrens, Bernd‐Arno; Raatz, Annika; Hübner, Sven; Bonk, Christian; Bohne, Florian; Bruns, Christopher; Micke-Camuz, Moritz

doi:10.1016/j.procir.2017.03.294

Cited by 49 publications

(21 citation statements)

References 13 publications

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“…To overcome these challenges, comprehensive iterative numerical and experimental investigations are required. Adjustments to the process parameters, the semi-finished product or the tool concept are typical measures to ensure component quality [2] Fig. 1.…”

Section: Thermof Thermoforming Pr Orming Process Ocessmentioning

confidence: 99%

“…Especially fibre-reinforced thermoplastics (FRTPs) are particularly suitable for largescale automotive production, as short cycle times can be achieved. Organo sheets or FRTP-tapes containing of continuous fibre reinforcements are commonly used to produce shell-shaped components like battery trays or seat shells [2,3]. Through an optional subsequent injection moulding process, stiffening or connecting elements can be generated through a substance bond to the organo sheet or FRTP-tape [4].…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

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Virtual parameter identification of the forming behaviour of discontinuous fibre reinforced thermoplastic composite sheets

Kabala¹,

Ossowski²,

Hürkamp³

et al. 2021

Esaform 2021

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Fibre-reinforced thermoplastics (FRTP), such as organo sheets or laminates, are increasingly being used in large-scale automotive production. The high weight-saving potential, high specific strengths and stiffnesses as well as processing times suitable for large-scale production are some of the reasons for using these materials. However, the formability of such semi-finished products is severely limited by the fibre reinforcement, which can lead to fibre breakage, fibre displacement or wrinkling in complex-shaped components. In order to increase the formability, an FRTP semi-finished product is developed, which consists of discontinuous tapes. Due to the local sliding of the tape sections, a pseudo-plastic material behaviour is achieved. Experimental uniaxial tensile tests at elevated temperatures are used to investigate the forming behaviour of the material for different tape lengths and overlap lengths. Subsequently, this tensile test is numerically modelled in order to fit the pseudo-plasticity to the experimental data by a virtual parameter identification. With the help of the parameters determined from the numerical tensile test, the sliding behaviour of the tape sections can be used for forming simulations in order to achieve a higher prediction quality.

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Section: Thermof Thermoforming Pr Orming Process Ocessmentioning

confidence: 99%

Section: Intr Introduction Oductionmentioning

confidence: 99%

Virtual parameter identification of the forming behaviour of discontinuous fibre reinforced thermoplastic composite sheets

Kabala¹,

Ossowski²,

Hürkamp³

et al. 2021

Esaform 2021

View full text Add to dashboard Cite

show abstract

“…Plies are generally picked up straight and placed straight down, e.g. [4,[40][41][42]. Alternatively, pick-up and place down is achieved through a rolling motion [22].…”

Section: Ply Handling Techniquesmentioning

confidence: 99%

Strategies for swift automated pick-and-place operations of multiple large-sized layers of reinforcement - a critical review

Zeeuw

Peeters

Bergsma

et al. 2020

Advanced Manufacturing: Polymer & Composites Science

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For the application of composite materials to become more widespread and replace traditional materials their manufacturing processes and final products will need to be competitive and be e.g. lighter, stronger or stiffer and quicker, easier or more cost-efficient to produce than traditional materials. The state of the art for pick-and-place operations for the manufacturing of composite parts focuses on handling single lab-sized layers at undisclosed speeds. The process could however be more competitive by being able to handle more and larger layers in a faster manner than currently presented in research. The aim of the paper is to evaluate the existing pick-and-place strategies on their suitability for the swift automated handling of multiple large-sized layers of reinforcement. The review shows that many of the existing techniques could be suitable for different scenario's and discusses which factors are to be taken into account when dealing with large layers, more than one layer or rapid handling.

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“…Thermoplastic composites (TPC) have an important contribution to modern lightweight construction due to their excellent density-related mechanical properties and established efficient production processes [1]. However, one of the obstacles for the use of TPC in multi-material systems is the availability of suitable joining technologies.…”

Section: Introductionmentioning

confidence: 99%

Joining of Thermoplastic Composites with Metals Using Resistance Element Welding

et al. 2020

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Joining is a key enabler for a successful application of thermoplastic composites (TPC) in future multi-material systems. To use joining technologies, such as resistance welding for composite-metal joints, auxiliary joining elements (weld inserts) can be integrated into the composite and used as an interface. The authors pursue the approach of embedding metal weld inserts in TPC during compression moulding without fibre damage. The technology is based on the concept of moulding holes by a pin and simultaneously placing the weld insert in the moulded hole. Subsequently, the composite component can be joined with metal structures using conventional spot welding guns. For this purpose, two different types of weld inserts were embedded in glass fibre reinforced polypropylene sheets and then welded to steel sheets. A simulation of the welding process determined suitable welding parameters. The quality of the joints was analysed by microsections before and after the welding process. In addition, the joint strength was evaluated by chisel tests as well as single-lap shear tests for the different weld insert designs. It could be shown that high-quality joints can be achieved by using the innovative technology and that the load-bearing capacity is significantly influenced by the weld inserts head design.

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Automated Stamp Forming of Continuous Fiber Reinforced Thermoplastics for Complex Shell Geometries

Cited by 49 publications

References 13 publications

Virtual parameter identification of the forming behaviour of discontinuous fibre reinforced thermoplastic composite sheets

Virtual parameter identification of the forming behaviour of discontinuous fibre reinforced thermoplastic composite sheets

Strategies for swift automated pick-and-place operations of multiple large-sized layers of reinforcement - a critical review

Joining of Thermoplastic Composites with Metals Using Resistance Element Welding

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