Building Block Approach’ for Structural Analysis of Thermoplastic Composite Components for Automotive Applications

Carello, Massimiliana; Amirth, N.; Airale, Andrea Giancarlo; Monti, Marco; Romeo, Andrea

doi:10.1007/s10443-017-9592-x

Cited by 16 publications

(12 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For instance, the aerospace industry exploits these benefits by replacing metals such as aluminium and titanium alloys with composites in primary structures such as the main wing and fuselage [1,2]. Similarly, the automotive industry is replacing more conventional materials with lighter and stiffer alternatives that meet the higher performance standards set by regulating bodies and tighter regulations and restrictions to produce environmentally friendly cars [3][4][5][6][7].…”

Section: Composites Joiningmentioning

confidence: 99%

Defects and uncertainties of adhesively bonded composite joints

2021

View full text Add to dashboard Cite

The increasing use of fibre reinforced polymer composite materials in a wide range of applications increases the use of similar and dissimilar joints. Traditional joining methods such as welding, mechanical fastening and riveting are challenging in composites due to their material properties, heterogeneous nature, and layup configuration. Adhesive bonding allows flexibility in materials selection and offers improved production efficiency from product design and manufacture to final assembly, enabling cost reduction. However, the performance of adhesively bonded composite structures cannot be fully verified by inspection and testing due to the unforeseen nature of defects and manufacturing uncertainties presented in this joining method. These uncertainties can manifest as kissing bonds, porosity and voids in the adhesive. As a result, the use of adhesively bonded joints is often constrained by conservative certification requirements, limiting the potential of composite materials in weight reduction, cost-saving, and performance. There is a need to identify these uncertainties and understand their effect when designing these adhesively bonded joints. This article aims to report and categorise these uncertainties, offering the reader a reliable and inclusive source to conduct further research, such as the development of probabilistic reliability-based design optimisation, sensitivity analysis, defect detection methods and process development.

show abstract

Section: Composites Joiningmentioning

confidence: 99%

Defects and uncertainties of adhesively bonded composite joints

2021

View full text Add to dashboard Cite

show abstract

“…The aim of this paper was to investigate on glass and carbon organosheets and carbon epoxy composites the influence of the thermoforming process on the final mechanical properties for the case study of Double Dome. In a previous work, Carello, Amirth et al (2017) considered a simple case study called Procomp, but it did not allow an in-depth evaluation of the fiber shear deformation [18,19]. The Double Dome has a more complex shape, and it was already investigated by Ford Research Lab (2004), in which it simulated a Twintex (glass fiber reinforced polypropylene) Double Dome thermoforming, and it evaluated the shear angle of the Double Dome after the simulation [20].…”

Section: Of 26mentioning

confidence: 99%

Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

et al. 2020

View full text Add to dashboard Cite

This research work investigated the influence of the press molding manufacturing process on the mechanical properties, both for thermoplastic and thermosetting fiber reinforced composite materials. The particular geometry of the case study, called Double Dome, was considered in order to verify the behavior of the Thermoplastic and Thermosetting prepreg in terms of shell thickness variation and fibers shear angle evolution during the thermoforming process. The thermoforming simulation was performed using LS-DYNA® Finite Element Analysis (FEA) code, and the results were transferred by Envyo®, a dedicated mapping tool, into a LS-DYNA® virtual model for the structural simulation. A series of Double Dome specimens was produced with industrial equipment, and a bending experimental test was been carried on. Finally, a numerical-experimental correlation was performed, highlighting a significant forecast of the mechanical properties for the considered component.

show abstract

“…Structural composite materials in sectors such as aerospace, automotive or renewable energy have significantly increased over the past decades, replacing traditional metals due to their superior mechanical properties, including high specific modulus [1,2]. The superior properties are established by tailoring the composite layout using appropriate resin matrix systems, combined with layered fibre reinforcement in different stack configurations and orientations to achieve the required mechanical properties [3,4]. Due to their complex nature, composites are subject to different failure types such as delamination, fibre breakage or cracks in the resin matrix [5,6].…”

Section: Introductionmentioning

confidence: 99%

Graphene-based strain sensing in composites for structural and health monitoring applications

et al. 2022

View full text Add to dashboard Cite

Composite structures are attracting more interest due to their outstanding mechanical properties; thus, their inspection and health assessment are key items for their safe use. In this article we present a graphene-based sensor that evaluates the strain generated within a composite. A finite element model was developed to investigate the mechanism driving the graphene to act as a strain sensor. A prototype sensor was manufactured, using a commercially available graphene ink. The strain in composite samples was measured and the gauge factor identified by applying different load scenarios. The graphene sensor proved to be able to evaluate strain at various levels providing a gauge factor (exceeding 6) higher than commercially available strain gauges. Article Highlights Graphene ink can be used to design and develop strain sensing systems Graphene strain sensors are printed directly on the material allowing great design flexibility. The sensors can either be applied on the surface of the composite material or embedded within the structure. The measured gauge factor for the graphene strain sensor is higher that the commercial strain sensors. The graphene strain sensors provided higher sensing capabilities compared to commercially available copper-based strain gauges. The graphene sensor showed consistent results for different mechanical testing scenarios. Graphical abstract

show abstract

Building Block Approach’ for Structural Analysis of Thermoplastic Composite Components for Automotive Applications

Cited by 16 publications

References 10 publications

Defects and uncertainties of adhesively bonded composite joints

Defects and uncertainties of adhesively bonded composite joints

Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

Graphene-based strain sensing in composites for structural and health monitoring applications

Contact Info

Product

Resources

About