Development and Numerical Validation of Combined Forming Processes for Production of Hybrid Parts

Behrens, Bernd‐Arno; Hübner, Sven; Chugreev, Alexander; Neumann, André; Grbic, Nenad; Schulze, Henrik; Lorenz, Ralph D.; Micke, Moritz; Bohne, Florian

doi:10.1007/978-3-662-58206-0_3

Cited by 2 publications

(2 citation statements)

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“…In addition, new industrial processing methods for FRP, such as thermoforming, are also becoming increasingly established [9]. The thermoforming of woven fabrics with a thermoplastic matrix material (for example, organo sheets) is one of the processes which is considered to have a high potential for the manufacturing of high-performance lightweight structures [10,11]. The combination of both processes in one step, known as a one-shot process, is a promising technology that makes it possible to apply geometrically complex functional elements to a basic carrier of thermoformed organo sheet by overmoulding a polymer.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Modelling of Bond Strength in Overmoulded Thermoplastic Composites

et al. 2021

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Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly functionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of overmoulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.

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Section: Introductionmentioning

confidence: 99%

“…Figure11. Influence of the geometry factor on the degree of intimate contact exemplary shown for the first and second rib of the lowest process parameter ("Low").…”

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confidence: 99%