Abstract
This paper gives an overview about different one-shot processes of hybrid forming and joining of semi-finished products using conventional forming presses. An example of forming with a variothermal tool is given by forming a sandwich structure. Different aspects of the forming process are addressed, including the interlayer formation during the process. Here, the objectives are the complete impregnation of the fibres, the consolidation and a firm bond. It is shown, that in contrast to that, the objective when forming a sandwich sheet is to prevent delamination. For forming a hybrid battery tray, a process was developed that combines the advantages of organic sheet forming and compression molding. In order to predict the quality of the bonding of the glass mat reinforced thermoplastic to the organic sheet the temperature evolution is numerically analysed.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
H. Palkowski, P. Giese, V. Wesling, G. Lange, S. Spieler, J. Göllner, Neuartige Sandwichverbunde – Herstellung, Umformverhalten, Fügen und Korrosionsverhalten, Material Science and Engineering Technology, 37, Issue 7, 2006, pp. 605–612.
G. Lange, Beitrag zum Umformverhalten von dreischichtigen austenitischen Sandwichverbunden mit polymerer Kernschicht, Dissertation, Technische Universität Clausthal, 2005.
H. C. Schmidt, C. Lauter, W. Homberg, Stahl-CFK-Strukturen, ILH insight – Forschung im Instititut für Leichtbau mit Hybridsystemen, 2013.
M.-S. Lee, S.-J. Kim, O.-D. Lim, C.-G. Kang, The effect of process parameters on epoxy flow behavior and formability with CR340/CFRP composites by different laminating in deep drawing process, Journal of Materials Processing Technology, 229, 2014, pp. 275–285.
H. Lohse, Thermoplastische Systemlösungen im Automobilbau, adhäsion KLEBEN & DICHTEN, 49, Issue 9, 2005, pp 22–27.
K. Großmann, S. Bräunling, A. Hardtmann, E. Staiger, T. Kerber, 3D-Textil-Blech-Verbunde, UTF Sience, 2, 2012.
E. Staiger, M. Hild, R.-D. Hyund, C. Cherif S. Bräuling, A. Hardtmann, Oberflächen haftungsgerecht gestalten, adhäsion KLEBEN & DICHTEN, 1-2, 2005, pp 32–35.
Institut für Leichtbau und Kunststofftechnik der Technischen Universität Dresden (Hrsg.), Höchstbelastete Pkw-B-Säule in Multi-Material-Design, ILK-aktuell, 01, 2015, pp. 3.
Audi AG, Werk Ingolstadt, Gemeinsamer Schlussbericht zum BMBF-Verbundprojekt „Herstellung von hybriden Leichtbau-Verbundrohren mit integrierten Funktionselementen durch Fluidinjektionstechnik ,FIT-Hybrid‘“, 2011.
J. Mitzler, J. Renkl, M. Würtele, Hoch beanspruchte Bauteile in Serie, Kunststoffe, 3, 2011, pp. 36–40.
D. Banabic, Sheet Metal Forming Process – Constitutive Modelling and Numerical Simulation, 1, Springer-Verlag Berlin Heidelberg, 2010.
B. Liang, N. Hamila, M. Peillon, P. Boisse, Analysis of thermoplastic prepreg bending stiffness during, Composites, Part A, , 2014, pp. 111–112.
F. Bohne, M. Micke-Camuz, M. Weinmann, C. Bonk, A. Bouguecha, B.-A. Behrens, Simulation of a Stamp Forming Process of an Organic Sheet and its Experimental Validation, 7. WGP-Jahreskongress Aachen, 2018, R. H. Schmitt, 2, pp. 11–19.
B.-A. Behrens, M. Vucetic, A. Neumann, T. Osiecki, N. Grbic, Experimental test and FEA of a sheet metal forming process of composite material and steel foil in sandwich design using LS-DYNA, Key Eng. Materials, 651-653, 2015, pp. 439–445.
B.-A. Behrens, S. Hübner, N. Grbic, M. Micke-Camuz, T. Wehrhane, A. Neumann, Forming and Joining of Carbon-Fibre-Reinforced-Thermoplastics and Sheet Metal in One Step, Procedia Engineering, 183, 2017, pp. 227–232.
ASTM, ASTM D5528: Standard Test Method for Mode I Interlaminar Fracture Toughness of Unidirectional Fiber-Reinforced Polymer Matrix Composites, ASTM International.
ASTM, ASTM D1876: Standard Test Method for Peel Resistance of Adhesives (T-Peel Test), ASTM International.
S. R. Hallet, P. W. Harper: Modelling delamination with cohesive elements, Numerical Modelling of Failure in Advanced Composite Materials, Woodhead Publishing Series in Composite Science and Engineering, 2015, pp. 55–72.
B.-A. Behrens, A. Bouguecha, C. Bonk, H. Schulze: Finite element analysis regarding the forming behaviour of symmetric hybrid structures consisting of two sheet metal outer layers and a thermoplastic core, IOP Conf. Series: Materials Science and Engineering 179, 2017.
B.-A. Behrens, A. Raatz, S. Hübner, C. Bonk, F. Bohne, C. Bruns, M. Micke-Camuz, Automated Stamp Forming of Continuous Fiber Reinforced Thermoplastics for Complex Shell Geometries, Procedia CIRP, 66, 2017, pp 113–118.
B.-A. Behrens, S. Hübner, C. Bonk, F. Bohne, M. Micke-Camuz, Development of a Combined Process of Organic Sheet forming and GMT Compression Molding, Procedia Engineering, 207, 2017, pp. 101–106.
B.-A. Behrens, A. Bouguecha, S. Hübner, C. Bonk, A. Neumann, N. Grbic, F. Bohne, M. Micke-Camuz, Umformtechnische Herstellung von hybriden Karosseriebauteilen aus Metallen und faserverstärkten Kunststoffen, 36. Verformungskundliches Kolloquium, Zauchensee, 2017.
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2019 Springer-Verlag GmbH Germany, part of Springer Nature
About this paper
Cite this paper
Behrens, BA. et al. (2019). DEVELOPMENT AND NUMERICAL VALIDATION OF COMBINED FORMING PROCESSES FOR PRODUCTION OF HYBRID PARTS. In: Dröder, K., Vietor, T. (eds) Technologies for economical and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-58206-0_3
Download citation
DOI: https://doi.org/10.1007/978-3-662-58206-0_3
Published:
Publisher Name: Springer Vieweg, Berlin, Heidelberg
Print ISBN: 978-3-662-58205-3
Online ISBN: 978-3-662-58206-0
eBook Packages: EngineeringEngineering (R0)