From UD-tape to Final Part – A Comprehensive Approach Towards Thermoplastic Composites

Kropka, Michael; Muehlbacher, M.; Neumeyer, Thomas; Altstaedt, Volker

doi:10.1016/j.procir.2017.03.371

Cited by 34 publications

(15 citation statements)

References 1 publication

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Another lever is the reduction of production waste, which accounts for the largest share of overall CFRP waste [142]. The large fraction of production scrap (25-30%) obstructs the use of organosheets based on woven fabrics to manufacture FRP parts [143]. Leveraging benefits of unidirectional fibre-reinforced tapes as a substitute for organosheets, Kropka et al developed a concept for a high-speed tape laying machine, which shows promising results regarding cycle time and scrap rate [143].…”

Section: Developments In Metal-and Frp Process Chains For Manufacturing Of Lightweight Structuresmentioning

confidence: 99%

“…The large fraction of production scrap (25-30%) obstructs the use of organosheets based on woven fabrics to manufacture FRP parts [143]. Leveraging benefits of unidirectional fibre-reinforced tapes as a substitute for organosheets, Kropka et al developed a concept for a high-speed tape laying machine, which shows promising results regarding cycle time and scrap rate [143]. Brecher et al improved the cost-and eco-efficiency of a high-speed tape placement operation for flat plates.…”

Section: Developments In Metal-and Frp Process Chains For Manufacturing Of Lightweight Structuresmentioning

confidence: 99%

See 1 more Smart Citation

Life cycle engineering of lightweight structures

et al. 2018

View full text Add to dashboard Cite

Lightweight structures are increasingly necessary to meet current engineering requirements. Weight reduction in diverse applications such as automobiles or machine tools is achieved either by using less material or by substituting material with a lighter one, which provides more functionality per unit of weight. To be an effective enabler for sustainability, lightweight structures should result in lower environmental impacts per functional unit when compared to conventional structures on a life cycle basis. However, applying new materials and manufacturing processes often leads to an increase in environmental impacts from the raw materials and production stage of the life cycle. Furthermore, end-of-life disassembly and recycling may become more difficult. In addition, the expected efficiency gains from the use of lightweight structures depend on how the overall market and technical systems respond to them. Consequently, the environmental evaluation of lightweight structures in engineering entails various methodological challenges. Organised around a life cycle engineering framework with a focus on eco-effectiveness, this paper provides a comprehensive review of lightweight structure applications and the challenges and opportunities they present in a life cycle engineering context.

show abstract

Section: Developments In Metal-and Frp Process Chains For Manufacturing Of Lightweight Structuresmentioning

confidence: 99%

Section: Developments In Metal-and Frp Process Chains For Manufacturing Of Lightweight Structuresmentioning

confidence: 99%

Life cycle engineering of lightweight structures

et al. 2018

View full text Add to dashboard Cite

show abstract

“…Fiber-reinforced composites can be classified into thermoset composites (TSCs) and thermoplastic composites (TPCs) owing to the difference in the resin matrix. Although the mechanical properties of TPCs differ from those of traditional TSCs, TPCs offer advantages of rapid prototyping [ 1 ], reprocessing, and environmental recycling [ 2 ]. Hence, TPCs are increasingly being valued and used in practical industries [ 3 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

et al. 2021

View full text Add to dashboard Cite

Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.

show abstract

“…In doing so, numerical simulations with adjusted material models do allow the prediction of the rate dependent non-linear mechanical behavior of complex shaped parts made out of TPCs [6]. Recent technology developments made in-situ thermoformed and overmolded laminate structures of TPCs available by hybrid injection molding, which enables the mass production of thermoplastic lightweight structures with a complex geometry and a high degree of functional integration [7]. The process flow of this technology is comparable to the already implemented Polymers 2021, 13, 3846 2 of 18 process flow of continuous fiber-reinforced thermoplastics consisting of textile fiber components and consist of the heating, hot handling and thermoforming of the TPC with subsequent overmolding in the same mold [8,9].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites

et al. 2021

View full text Add to dashboard Cite

In-situ thermoforming and overmolding of continuous fiber-reinforced thermoplastic composites by hybrid injection molding enables the mass production of thermoplastic lightweight structures with a complex geometry. In this study, the anisotropic mechanical behavior of such hybrid injection molded short and continuous fiber-reinforced thermoplastics and the numerical simulation of the resulting mechanical properties under flexural loading were investigated. For this, the influence of the volume flow rate between 25 and 100 cm3/s during injection molding of a PP/GF30 short fiber-reinforced overmolding material was studied and showed a strong effect on the fiber orientation but not on the fiber length, as investigated by computer tomography and fiber length analysis. Thus, the resulting anisotropies of the stiffness and strength as well as the strain hardening investigated by tensile testing were considered when the mechanical behavior of a hybrid test structure of short and continuous fiber-reinforced thermoplastic composites was predicted by numerical simulations. For this, a PP/GF60 and PP/GF30 hybrid injection molded test structure was investigated by a numerical workflow with implemented injection molding simulation data. In result, the prediction of the mechanical behavior of the hybrid test structure under flexural loading by numerical simulation was significantly improved, leading to a reduction of the deviation of the numerically predicted and experimentally measured flexural strength from 21% to 9% in comparison to the isotropic material model without the implementation of the injection molding data.

show abstract

From UD-tape to Final Part – A Comprehensive Approach Towards Thermoplastic Composites

Cited by 34 publications

References 1 publication

Life cycle engineering of lightweight structures

Life cycle engineering of lightweight structures

Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites

Contact Info

Product

Resources

About