Model-Based Estimation of the Strength of Laser-Based Plastic-Metal Joints Using Finite Element Microstructure Models and Regression Models

Berges, Julius Moritz; Straeten, Kira van der; Jacobs, Georg; Berroth, Joerg; Gillner, Arnold

doi:10.3390/ma14175004

Cited by 3 publications

(2 citation statements)

References 36 publications

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“…Mechanical Model. The optimization approach is performed using a 2D finite element micro model of a single lap joint specimen (Steel 1.4301, Plastic PP/GF40) as presented in [6] and shown in Fig. 2a.…”

Section: Models and Optimization Approachmentioning

confidence: 99%

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Towards a Model-Based Approach for the Optimization of the Mechanical and Economical Properties of Laser-Based Plastic-Metal Joints

Berges

Straeten

Jacobs

et al. 2022

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The application of laser-structured metal surfaces to combine plastics and metals is a promising option to enable low-cost lightweight and resource-efficient multi-material joints. The mechanical properties (especially strength), as well as production time and costs, depend on the microstructure of the metal surface (e.g. the number, distance and shape of cavities). Thus, in order to design optimal joints, the properties from the mechanical, as well as production and cost domain, must be considered simultaneously during product development. Therefore, in this paper, a model-based optimization approach is presented with the goal of identifying an optimum between the strength of the joint and laser manufacturing costs. Parameterized models for the strength estimation, as well as calculation of laser manufacturing time and costs, are developed. The models are linked in an optimization workflow and the optimum positioning and shape of the cavities on the joining zone is determined using a genetic optimization algorithm. The results show that, compared to a benchmark, the manufacturing costs can be reduced by 82 % for the same strength using the proposed model-based optimization approach.

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Section: Models and Optimization Approachmentioning

confidence: 99%

“…1 step 1). Examples of cavity shapes for two to seven runs can be found in [6]. Theoretically, any geometric pattern can be created on the metal surface.…”

Section: Introductionmentioning

confidence: 99%

Towards a Model-Based Approach for the Optimization of the Mechanical and Economical Properties of Laser-Based Plastic-Metal Joints

Berges

Straeten

Jacobs

et al. 2022

KEM

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Classification of Simulation Models for the Model-based Design of Plastic-Metal Hybrid Joints

et al. 2022

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A Numerical Approach for the Efficient Concept Design of Laser-Based Hybrid Joints

2022

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Laser-based plastic–metal joints have high potential to enable cost-efficient lightweight structures in multi-material design. By an appropriate load-optimized positioning of the microstructure on the joining zone, cost- and strength-optimized joints can be realized. However, there are no design methods and models to efficiently develop these tailored microstructures. Currently, time-consuming experiments are necessary to find the optimum microstructure concepts. These experiments must be repeated when requirements change, e.g., dimensions of the components. To provide a simple and efficient design tool, this paper presents an automated numerical method for the development of cost- and strength-optimized microstructure concepts for laser-based joining zones. The basis for the approach is a new numerical model which generates concepts for microstructures automatically based only on the stress tensor in the joining zone. A new finite element cohesive zone model (CZM) was developed to estimate the joint strength. The CZM parameters were efficiently derived from a finite element model of a single cavity. To determine the costs, a new model is presented that calculates the production time and the cost for any given microstructure. The models were interconnected in a combined optimization procedure and a genetic algorithm was used to determine cost- and strength-optimized microstructure concepts. The approach was applied to a demonstration example where the laser costs were reduced by up to 67% compared with benchmarks with surface-covering parallel linear cavities. The approach shows high potential for the efficient design of cost- and strength-optimal laser-based hybrid joints since it is fully based on simulation models and iterative experiments in the design stage are eliminated.

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Model-Based Estimation of the Strength of Laser-Based Plastic-Metal Joints Using Finite Element Microstructure Models and Regression Models

Cited by 3 publications

References 36 publications

Towards a Model-Based Approach for the Optimization of the Mechanical and Economical Properties of Laser-Based Plastic-Metal Joints

Towards a Model-Based Approach for the Optimization of the Mechanical and Economical Properties of Laser-Based Plastic-Metal Joints

Classification of Simulation Models for the Model-based Design of Plastic-Metal Hybrid Joints

A Numerical Approach for the Efficient Concept Design of Laser-Based Hybrid Joints

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