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Investigation of manufacturing process effects on microstructure and fatigue prediction in composite automotive tailgate design

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Abstract

Manufacturing processes significantly influence microstructural variations in short fiber reinforced composites, which affect damage characteristics and fatigue life. Accurate fatigue life prediction is critical, especially when considering the impact of these manufacturing induced microstructural nuances. In this study, we investigate how manufacturing processes shape microstructures and their impact on fatigue life prediction. We present an advanced micromechanical model for predicting fatigue life in tangible structures, considering the microstructure distribution influenced by manufacturing dynamics. Our model links damage from monotonic loading to fatigue life, resulting in a multi-scale fatigue prediction model. This approach builds a database revealing the interaction between Tsai-Wu failure criterion parameters, manufacturing-induced microstructural variations, and target fatigue life. Using these insights, we fine-tune material properties in finite element simulations for precise design optimization. We illustrate our method using an automotive tailgate made from a sheet molding compound. This research highlights the critical role of manufacturing processes in microstructure variation and fatigue life prediction. It offers the potential for significant vehicle weight reduction, energy savings, and reduced emissions in automotive design and promises to be a valuable tool for optimizing manufacturing process parameters.

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The authors declare that the data and the materials of this study are available within the article.

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Author information

Authors and Affiliations

  1. Arts Et Metiers Institute of Technology, CNAM, CNRS, PIMM, HESAM University, 75013, Paris, France

    Joseph Fitoussi, Samia Nouira & Mohammadali Shirinbayan

  2. Arts Et Metiers Institute of Technology, CNAM, LCPI, HESAM University, 75013, Paris, France

    Khaled Benfriha

  3. University of Bordeaux, ESTIA Institut de Technologie, Technopôle Izarbel, 64210, Bidart, France

    Mohamed Amine Laribi

  4. Léonard de Vinci Pôle Universitaire, Research Center, La Défense, 92916, Paris, France

    Achraf Kallel

  5. Zero Emission, FORVIA Clean Mobility, Bois Sur Prés, 25550, Bavans, France

    Robert Tie Bi

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Contributions

JF, MAL, and MS: construct the idea. JF, SN, KB, MAL, AK, RTB, and MS: analyzed results, draft manuscript preparation, and wrote the paper. JF, SN, KB, MAL, AK, RTB, and MS: corrected the English and the paper format.

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Correspondence to Mohammadali Shirinbayan.

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Fitoussi, J., Nouira, S., Benfriha, K. et al. Investigation of manufacturing process effects on microstructure and fatigue prediction in composite automotive tailgate design. Int J Adv Manuf Technol 130, 4295–4310 (2024). https://doi.org/10.1007/s00170-024-12988-z

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