FE Crash Modeling of Aluminum-FRP Hybrid Components Manufactured by a Hybrid Forming Process

Abstract

Through the patented process of hybrid forming [1], it is possible to produce a bonded metal-plastic-hybrid component in one process step with the help of an edge-sealed pressing tool. Such a component exhibits an enormous energy absorption potential. To use this complete potential, a reliable FE-Modelling is necessary, that can exactly replicate the complex material layup consisting of an isotropic metal, a very thin bonding layer, and an anisotropic glass mat reinforced thermoplastic (GMT) for crash load case. A methodology is proposed to numerically predict the behavior of the metal GMT aluminum components. And finally, the experimental results of Hybrid components are validated for three-point bending and axial crash load cases.