Computational analysis of injection-molding residual-stress development in direct-adhesion polymer-to-metal hybrid body-in-white components

Grujičić, M.; Sellappan, V.; Pandurangan, B.; Li, G.; Vahidi, Ardalan; Seyr, Norbert; Erdmann, Marc; Holzleitner, Jochen

doi:10.1016/j.jmatprotec.2007.09.059

Cited by 24 publications

(17 citation statements)

References 24 publications

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“…Adhesively bonded metalplastic composites offer advantages over riveted structures, overmolding via mechanical interlocking and other mechanical joining techniques because it yields a continuous bond between the two substrates, minimizes stress, and acts as a buffer between the metal and plastic to absorb impact. 5,[8][9][10][11][12] Additional technical challenges still exist for bonded repairs before widespread implementation can be achieved. This includes qualification of the adhesive bonding process in terms of bond strength and durability.…”

Section: Introductionmentioning

confidence: 99%

Atmospheric pressure plasma effects on the adhesive bonding properties of stainless steel and epoxy composites

Williams

Yeh

et al. 2012

Journal of Composite Materials

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An atmospheric pressure helium and oxygen plasma has been used for the surface preparation of 410 stainless steel and carbon-fiber epoxy laminates prior to bonding to themselves or to each other. Lap shear results for stainless steel coupons and carbon-fiber epoxy laminates demonstrated an 80% and a 150% increase in bond strength, respectively, after plasma activation. Following 7 days of aging, wedge crack extension tests revealed a crack extension length of 7.0 mm and 2.5 mm for the untreated and plasma-activated steel. The untreated stainless steel had 30% cohesive failure compared to 97% for steel activated with the plasma. Surface analysis by X-ray photoelectron spectroscopy showed that carbonaceous contamination was removed by plasma treatment, and specific functional groups, e.g. carboxylic acids, were formed on the surface. These functional groups promoted strong chemical bonding to the epoxy film adhesive. Atmospheric pressure plasmas are an attractive alternative to abrasion techniques for surface preparation prior to bonding.

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Section: Introductionmentioning

confidence: 99%

Atmospheric pressure plasma effects on the adhesive bonding properties of stainless steel and epoxy composites

Williams

Yeh

et al. 2012

Journal of Composite Materials

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“…In other words, joints between the composite-laminate inner panel and thread joining components will be treated as adhesively bonded, but the cohesion-zone stiffness and strength parameters of the joint will be increased in order to account for the effect of the rivets. Such an approach was developed in our recent work [20] and hence, will not be discussed in great details here.…”

Section: Durability Analysismentioning

confidence: 99%

“…Within the finite-element durability analysis carried out here, cohesive elements available in Abaqus/Standard were used to represent the adhesive-bonded composite-laminate/sheet-metal joints. A detailed account of this approach including the assessment of the initial (intact) cohesive zone parameters and their finite element implementation can be found in our recent work [20].…”

Section: Durability Analysismentioning

confidence: 99%

Multi-Disciplinary Design Optimization of a Composite Car Door for Structural Performance, NVH, Crashworthiness, Durability and Manufacturability

Grujicic¹,

Arakere²,

Sellappan³

et al. 2009

Multidiscipline Modeling in Materials and Structures

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Among various efforts pursued to produce fuel efficient vehicles, light weight engineering (i.e. the use of low-density structurally-efficient materials, the application of advanced manufacturing and joining technologies and the design of highly-integrated, multi-functional components/sub-assemblies) plays a prominent role. In the present work, a multidisciplinary design optimization methodology has been presented and subsequently applied to the development of a light composite vehicle door (more specifically, to an inner door panel). The door design has been optimized with respect to its weight while meeting the requirements /constraints pertaining to the structural and NVH performances, crashworthiness, durability and manufacturability. In the optimization procedure, the number and orientation of the composite plies, the local laminate thickness and the shape of different door panel segments (each characterized by a given composite-lay-up architecture and uniform ply thicknesses) are used as design variables. The methodology developed in the present work is subsequently used to carry out weight optimization of the front door on Ford Taurus, model year 2001. The emphasis in the present work is placed on highlighting the scientific and engineering issues accompanying multidisciplinary design optimization and less on the outcome of the optimization analysis and the computational resources/architecture needed to support such activity.

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“…Researchers have studied insert molding of metals in polymers in several applications over the past few years [5,6]. They have developed methods for using metals as reinforcing structures in injection molded polymer parts.…”

Section: Introductionmentioning

confidence: 99%

Design of Revolute Joints for In-Mold Assembly Using Insert Molding

Ananthanarayanan

Ehrlich

Desai

et al. 2011

Journal of Mechanical Design

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Creating highly articulated miniature structures requires assembling a large number of small parts. This is a very challenging task and increases cost of mechanical assemblies. Insert molding presents the possibility of creating a highly articulated structure in a single molding step. This can be accomplished by placing multiple metallic bearings in the mold and injecting plastic on top of them. In theory, this idea can generate a multi degree of freedom structures in just one processing step without requiring any post molding assembly operations. However, the polymer material has a tendency to shrink on top of the metal bearings and hence jam the joints. Hence, until now insert molding has not been used to create articulated structures. This paper presents a theoretical model for estimating the extent of joint jamming that occurs due to the shrinkage of the polymer on top of the metal bearings. The level of joint jamming is seen as the effective torque needed to overcome the friction in the revolute joints formed by insert molding. We then use this model to select the optimum design parameters which can be used to fabricate functional, highly articulating assemblies while meeting manufacturing constraints. Our analysis shows that the strength of weld-lines formed during the in-mold assembly process play a significant role in determining the minimum joint dimensions necessary for fabricating functional revolute joints. We have used the models and methods described in this paper to successfully fabricate the structure for a minimally invasive medical robot prototype with potential applications in neurosurgery. To the best of our knowledge, this is the first demonstration of building an articulated structure with multiple degrees of freedom using insert molding.

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Computational analysis of injection-molding residual-stress development in direct-adhesion polymer-to-metal hybrid body-in-white components

Cited by 24 publications

References 24 publications

Atmospheric pressure plasma effects on the adhesive bonding properties of stainless steel and epoxy composites

Atmospheric pressure plasma effects on the adhesive bonding properties of stainless steel and epoxy composites

Multi-Disciplinary Design Optimization of a Composite Car Door for Structural Performance, NVH, Crashworthiness, Durability and Manufacturability

Design of Revolute Joints for In-Mold Assembly Using Insert Molding

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