Hybrid forming of sheet metals with long Fiber-reinforced thermoplastics (LFT) by a combined deep drawing and compression molding process

Fang, Xiangfan; Kloska, Tobias

doi:10.1007/s12289-019-01493-4

Cited by 18 publications

(19 citation statements)

References 8 publications

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“…Due to the lack of fail-safe behavior of FRPs, the idea of hybrid forming was developed to produce a metal-FRP multi-material component with material-based large-area joining between metal sheets and FRPs [11]. The FRP may have different thicknesses and rib structures to effectively reinforce the sheet metal panels.…”

Section: Principle Of the Hybrid Forming Methodsmentioning

confidence: 99%

“…Since the thermoplastic composite materials for FRP compression molding, such as PP or PA (with fibers like GF), are in a half-liquid state before compression molding, they can also be used as pressure media. This combined method is called the hybrid forming of sheet metal and FRPs [11].…”

Section: Principle Of the Hybrid Forming Methodsmentioning

confidence: 99%

“…The blank holder was supported by a die cushion with adjustable forces. Detailed descriptions can be found in [11]. The first hybrid forming experiments with this die showed leakage of LFT in the corner areas due to wrinkles, which are typical when sheet metals deform in a strong deep draw mode.…”

Section: Tube Geometrymentioning

confidence: 99%

“…Moreover, since the fibers are only subjected to shear stress when filling the die cavity (no nuzzles), the fiber length degradation is significantly reduced compared to injection molding. Fiber lengths of up to 10 mm could be achieved for a PP glass fiber (GF) material [11], which is thus referred to as long fiber thermoplastic (LFT). According to [12], the material properties significantly depend on fiber length.…”

Section: Introductionmentioning

confidence: 99%

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Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Fang¹,

Kloska²,

Hajdarevic³

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Fiber-reinforced plastics (FRPs) are increasingly being used to reinforce steel or aluminum (Al) automotive structure components. Currently, these multi-material applications are realized via three-stage manufacturing, which require the corresponding costs. Thus, a new hybrid forming technology has been developed and will be presented here. It is based on the principle of the hydro-mechanical sheet metal-forming technique and uses a heated thermoplastic FRP material (up to 280°C) in a half melting state as the pressure media to form steel or aluminum sheets. Since the sheet metals are pre-coated with an adhesion promoter, the FRPs are also joined with the sheet metal during this hybrid forming process. In this work, the die and especially the sealing concepts for hybrid forming will be introduced based on different part geometries. The formability of the sheet metals (Nakajima test) at different temperatures up to 280°C, for each two steel and Al alloys, will be presented. The hybrid formed parts were analyzed using optical method and section analysis. Good forming results were confirmed for both sheet metal and FRPs. A vehicle chassis component was successfully hybrid formed using CP-W800 steel and FRP, and a body component was produced using an Al5182 alloy and an FRP.

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Section: Principle Of the Hybrid Forming Methodsmentioning

confidence: 99%

Section: Principle Of the Hybrid Forming Methodsmentioning

confidence: 99%

Section: Tube Geometrymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Fang¹,

Kloska²,

Hajdarevic³

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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“…New mechanical fastening methods have been proposed as joining processes to manufacture dissimilar parts [1,2]. Among these, friction stir based techniques have been developed in different variants [3,4].…”

Section: Introductionmentioning

confidence: 99%

A novel sensitivity analysis on friction spot joining process performed on aluminum\polycarbonate sheets by simulation

et al. 2020

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The manufacturing research has been focusing on the improvement of product performance and lightweight design. The synergic effects between material properties and manufacturing solutions have been considered, extensively. Specifically, joining techniques have been developing with the aim to propose new suitable solutions considering dissimilarities in the properties of the materials that have to be combined. Setting of new manufacturing routes is, therefore, a demanding task. In this direction, there are several methods available in the scientific literature that are focused on sensitivity analysis or optimization/minimization techniques to reduce the necessary attempts or to find a solution/correlation among big data. In this work, the goal of obtaining high joint efficiency between Aluminum and Polycarbonate sheets by the Friction Spot Joining process is considered as a case study. This process must face two main issues, i.e., the mechanical, physical and chemical compatibilities between the parts and the integrity protection of the polymeric sheet near the joining area. The process parameters influences were analysed using numerical simulations performed by a commercial FE code. The number of executed analyses was reduced with a planned DoE. From these results, the Code2Vect algorithm was employed with the aim to visualize, efficiently, high-dimensional data and to evaluate the influences of some identified parameters on the process answer. Finally, a transfer function involving the input and output quantities of interest was derived in a compact representation by a Newton Raphson minimization technique.

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Development of a kinematic model for a free kinematic forming process to compute the tool trajectory

Ekanayaka,

Hürkamp,

Dröder

2024

Proc Appl Math and Mech

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In the production of hybrid composites made of thermoplast and metal sheets, certain limitations in the linear forming process can be overcome through a free kinematic forming process. This process involves distributing the thermoplast press mass using a tumbling or cyclic rolling movement of the forming tool. Due to this special kinematics, only a small part of the tool is ever in engagement with the workpiece, so the component is formed incrementally. Therefore, the final geometry does not have to be created in one stroke but can be carried out step by step in several partial strokes. In order to determine the optimal trajectory of the forming tool, the kinematic interplay between the workpiece, forming tool, and toolpath should be numerically captured in a mathematical model. The specific toolpath depends on the component being formed, as well as the actual geometry of the forming tool. In this research, the free kinematic forming process is modeled and the optimal toolpath is determined using a genetic algorithm. The optimal toolpath enables a uniform distribution of the thermoplast to a specified thickness and collisions between the upper and lower tool are avoided. This enables key insights into the free kinematic forming process and opens up further avenues of research for this innovative and future‐oriented manufacturing concept.

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Hybrid forming of sheet metals with long Fiber-reinforced thermoplastics (LFT) by a combined deep drawing and compression molding process

Cited by 18 publications

References 8 publications

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

A novel sensitivity analysis on friction spot joining process performed on aluminum\polycarbonate sheets by simulation

Development of a kinematic model for a free kinematic forming process to compute the tool trajectory

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