Project Details
Projekt
Basic research on intrinsically produced FRP-/metal-composites - from embedded inserts to load-bearing hybrid structures
Applicants
Professor Dr.-Ing. Jürgen Fleischer; Professor Dr.-Ing. Frank Henning; Professor Dr.-Ing. Kay A. Weidenmann
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Plastics Engineering
Production Automation and Assembly Technology
Plastics Engineering
Production Automation and Assembly Technology
Term
from 2014 to 2018
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 255854000
Phase II of the project "basic research of intrinsically made FRP-/metal composites - from the embedded insert to load-bearing hybrid structure" deals with the production, the characterisation and the simulation of a CFRP/steel structural component. All project participants first transfer the knowledge gained in phase I of the project on load introducing elements, which are punctual and linear, to a differential design. This is based on the combination of several inserts and a subsequently attached metallic hat profile so as to obtain a hybrid component with a metallic, supporting component. An integral hybrid structure is to be derived from this. The CFRP/steel structural components should be intrinsically hybridised, i.e. in a direct production process. This hybridization is based on the use of a steel blade in the form of a hat profile, which is to be inserted by fiber in such a way that a structural load is optimally introduced into the CFRP laminate. Thus, the metallic component accepts a load-bearing function in the component, which provides by the intrinsic manufacturing advantages in terms of load capacity. By combining the advantages of both materials, the specific energy absorption capacity and the light construction potential can be increased. Possible applications are, for example, automobile body components, such as side impact carriers, B-pillars or transverse or longitudinal carriers. The wbk - Institute for Production Engineering deals with the production of differential and integral designs. The intrinsic production of the integral structure involves a systematic study of the associated process parameters in order to achieve a reproducible and high sample quality and thus to build up a comprehensive process understanding for complex components. Moreover, different introduction concepts and installation positions and an optimum ratio of FRP and metal are to be investigated. The institute for applied materials (IAM-WK) is concerned with the study of the integral and differential bearing structures under stresses close to the structural part, including the investigation according to the respective damage evolution, in order to obtain a comprehensive understanding of the process-structure-property relations. The institute of vehicle system technology (FAST) deals with the prediction of mold filling, residual stresses and failure behavior of the hybrid component under quasi-static bending stress, taking into consideration the production effects. Material behavior is characterized by using full-field optical measurement of the displacement and expansion field of samples exposed to thermal and mechanical loads. Furthermore, the structure simulation is coupled with the process simulation in order to be able to optimize the hybrid structure and the manufacturing process in a holistic way.
DFG Programme
Priority Programmes
