JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 37
Fig. 4: Influence of fibre orientation in the contacted layer on the bond strength
Fig. 5: Medial forces and maximum displacements of double-Z profile samples under pressure crash loads
under crash loads. For a fundamental qualification, several combinations of double-Z profiles made of 1.5 and 2 mm DD11 steel and 9-layer CFRP reinforcements were produced. These profiles were tested on a carriage crash test facility under compression forces comparable to an automotive crash box. Figure 5 illustrates the results of the crash tests (Fig. 5). The medial force and the maximum displacement for mere steel and hybrid structures with different wall thicknesses are shown in the diagram. To analyse the lightweight potential in detail, the values were referred to the weight of the samples. As a result, the medial specific force for the 3.5 mm hybrid solution is for example twice the value of the 1.5 mm mere steel solution: 60 N/g for the hybrid compared to 30 N/g for the steel structure. As a first result, it can be stated that hybrid materials offer a significant weight saving potential. The next step is to increase the number of crash tests. This means to vary steel materials, prepreg layers and forces, for example three-point bending.
This procedure can be used to manufacture automotive structures, for example b-pillars or rocker panels, within cycle times of less than 5 minutes compared to typically 15 minutes. Using multiple tools or multiple flexible press devices allows a further reduction of cycle times (Fig. 6 b) because this concept significantly reduces down time.
Conclusions
Hybrid systems consisting of sheet metal and fibre-reinforced plastics offer a major potential for lightweight design in the automotive industry. The prepreg press technology can significantly reduce the number of process steps and process times compared to the current solutions. By using the prepreg press technology, CFRP prepregs are formed into steel structures. Bonding is achieved using the epoxy resin as an adhesive, which offers a high joint strength. Furthermore, it has been shown that the structures offer a high crash performance. n
Fig. 6: Automated prepreg-press process a) with a single press device and a double mould, and b) with multiple flexible press devices
Approaches for mass production
Substantial demands to implement hybrid structures into automotive applications are adequate approaches for mass production. The prepreg press technology can meet this demand by the use of automation tools like robots or assembly lines (Fig. 6 a). In this case, a robot inserts formed sheet metal into a heated mould. The same robot inserts a tailored prepreg. Forming and curing are carried out as described before.
More information: christian.lauter@uni-paderborn.de
Acknowledgements The authors would like to thank the EFRE fund of the EU and the state of North RhineWestphalia for supporting the research project within the scope of the Ziel 2 programme. Furthermore, we gratefully acknowledge the support by our project partners Benteler-SGL, Audi, and Johann Meier Werkzeugbau and the cooperating Chairs of the University of Paderborn, LUF, LTM and LWK.
No69 November - December 2011 / jec composites magazine
References [1] D. Lutz: “Chassis lightweight design exemplified on a suspension strut – State of the art and potential”. Proceedings of 11. Aachen Colloquium Automobile and Engine Technology, Aachen, pp. 437-455, 2002. [2] A. Horoschenkoff: “Statt Stahl und Aluminium”. Kunststoffe, No. 5, pp. 50-54, 2010. [3] S. Grasser: “Composite-MetallHybridstrukturen unter Berücksichtigung großserientauglicher Fertigungsprozesse”. Proceedings of Symposium Material Innovativ, Ansbach, 2009. [4] M. Maciej: “Faserverbundkunststoffe: Von der Kleinserienfertigung von Sichtbauteilen zur Großserienproduktion von Strukturteilen”. Proceedings of InnoMateria – Interdisziplinäre Kongressmesse für innovative Werkstoffe, Köln, 2011. [5] S. P. McEntee and C. M. O’Bradaigh: “Large deformation finite element modelling of single-curvature composite sheet forming with tool contact”. Composites, Part A26A, pp. 207213, 1998.
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Feature land transportation
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011
Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011
Cover
Edito
Point of view - Umeco: focused on growth
Contents
Agenda of Events
COMPANY & BUSINESS
- In brief
- Australia - A continuous fibre tissue machine at Regina Glass Fibre
APPLICATIONS
- Marine - Signature marine projects and record-breaking super yacht
- Automotive - World’s first production-ready thermoplastic wheel rim
- Building & construction - A definite and technical success to help the fight against AIDS
MARKET
- China - The Chinese composite market: bright prospects
- CFRP - Wind surpasses aerospace as top user of advanced compositematerials
- Sustainability - Acting on sustainability for business value
FEATURE LAND TRANSPORTATION
- Raw material - Resin and gelcoat compliant with the new railway standard
- Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
- Sandwich construction - Rolling stock: weight reduction pays off
- CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
- Design - Next generation composites – driving innovation in the ground transportation sector
- Structures - Hybrid structures for tailored structural automotive components
- Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
RESEARCH & DEVELOPMENT
- Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
- Bonding - 3D sandwich panel manufacturing with great properties as result
TECHNOLOGY & INNOVATIONS
- Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
- Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
- Manufacturing - New mould manufacturing process
- Foam - A new product range for marine applications
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Cover
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 2
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Edito
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Point of view - Umeco: focused on growth
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 5
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Contents
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 7
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 8
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - COMPANY & BUSINESS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - In brief
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Australia - A continuous fibre tissue machine at Regina Glass Fibre
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Marine - Signature marine projects and record-breaking super yacht
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 13
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Automotive - World’s first production-ready thermoplastic wheel rim
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Building & construction - A definite and technical success to help the fight against AIDS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 16
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 17
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - China - The Chinese composite market: bright prospects
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 19
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - Wind surpasses aerospace as top user of advanced compositematerials
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sustainability - Acting on sustainability for business value
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 22
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 23
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Raw material - Resin and gelcoat compliant with the new railway standard
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 25
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 26
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sandwich construction - Rolling stock: weight reduction pays off
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 29
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 31
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Design - Next generation composites – driving innovation in the ground transportation sector
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 33
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 34
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Structures - Hybrid structures for tailored structural automotive components
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 36
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 37
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 40
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 41
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 42
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 43
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 44
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Bonding - 3D sandwich panel manufacturing with great properties as result
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 46
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 47
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 48
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 50
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 51
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 53
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Manufacturing - New mould manufacturing process
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 55
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Foam - A new product range for marine applications
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Index
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 59
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 60
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