TY - GEN

T1 - A novel method for manufacturing of hybrid structures made of metal and fiber reinforced plastics using a multidirectional forming process

AU - Holt, Johannes

AU - Behrens, Bernd-Arno

AU - Uhe, Johanna

AU - Wester, Hendrik

N1 - Publisher Copyright: © 2024 Tanger Ltd., Ostrava.

PY - 2024/6/26

Y1 - 2024/6/26

N2 - Hybrid materials are increasingly used in lightweight construction. The combination of metallic materials with fiber-reinforced plastics (FRP) can reduce weight and improve the mechanical properties of a component. FRP are known for their lightweight and corrosion resistance, while metals show high strengths and stiffnesses. In order to combine the advantages of both materials, it is possible to reinforce highly stressed segments of a metallic component with FRP. A novel method for manufacturing such hybrid metal-FRP composite structures using a multidirectional forming process is investigated. Thereby, a glass mat reinforced thermoplastic (GMT), consisting of a polypropylene matrix with 40% glass fiber reinforcement, is compression moulded on specific segments of a metallic component by means of a controlled multidirectional die. For this, finite element (FE) simulations are required to design a forming process close to an industrial application. In order to conduct such a numerical study of the material flow during forming, a precise characterization of the GMT is necessary. Therefore, isothermal compression tests were conducted using a parallel-plate rheometer at different temperatures ranging from 180 °C to 220 °C and varying squeeze rates from 0.05 mm/s to 2 mm/s. The experimental data is used to fit a material model for the FE simulations. To verify the material model for further simulations in the project, the compression process is simulated in ABAQUS using a Coupled Eulerian-Lagrange approach and the results are compared with the experimental data.

AB - Hybrid materials are increasingly used in lightweight construction. The combination of metallic materials with fiber-reinforced plastics (FRP) can reduce weight and improve the mechanical properties of a component. FRP are known for their lightweight and corrosion resistance, while metals show high strengths and stiffnesses. In order to combine the advantages of both materials, it is possible to reinforce highly stressed segments of a metallic component with FRP. A novel method for manufacturing such hybrid metal-FRP composite structures using a multidirectional forming process is investigated. Thereby, a glass mat reinforced thermoplastic (GMT), consisting of a polypropylene matrix with 40% glass fiber reinforcement, is compression moulded on specific segments of a metallic component by means of a controlled multidirectional die. For this, finite element (FE) simulations are required to design a forming process close to an industrial application. In order to conduct such a numerical study of the material flow during forming, a precise characterization of the GMT is necessary. Therefore, isothermal compression tests were conducted using a parallel-plate rheometer at different temperatures ranging from 180 °C to 220 °C and varying squeeze rates from 0.05 mm/s to 2 mm/s. The experimental data is used to fit a material model for the FE simulations. To verify the material model for further simulations in the project, the compression process is simulated in ABAQUS using a Coupled Eulerian-Lagrange approach and the results are compared with the experimental data.

KW - Composite materials

KW - glass mat reinforced thermoplastic

KW - multidirectional forming process

KW - numerical simulation

UR - http://www.scopus.com/inward/record.url?scp=105003729930&partnerID=8YFLogxK

U2 - 10.37904/metal.2024.4904

DO - 10.37904/metal.2024.4904

M3 - Conference contribution

T3 - Metal

SP - 456

EP - 460

BT - METAL Conference Proeedings

ER -