Manufacturing distortions of a CFRP box-structure – A semi-numerical prediction approach

Kappel, Erik; Stefaniak, Daniel; Holzhüter, Dirk; Hühne, Christian; Sinapius, Michael

doi:10.1016/j.compositesa.2013.04.003

Cited by 50 publications

(11 citation statements)

References 9 publications

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“…Good prediction accuracy by using FEM was also re ported by Darrow and Smith [262] and Fernlund et al [246]. Kappel et al [265,272], present a semi numerical distortion simulation strategy by combining experimental, analytical and numerical proce dures. The developed FE method is very efficient due to the use of standard shell elements and the demand of only one input parameter derived from spring in of L profiles.…”

Section: Analytical and Numerical Prediction Of Geometrical Deviationsmentioning

confidence: 93%

Fast processing and continuous simulation of automotive structural composite components

Henning

Kärger

Dörr

et al. 2019

Composites Science and Technology

120

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Due to application-specific tailoring, continuous fiber reinforced plastics (CoFRP) provide an exceptional lightweight potential and are particularly suited for structural components. The use of CoFRP specifically for weight reduction of the automotive car body is the major focus of this feature article. Automotive mass production requires fast and qualified, thus highly automated and material efficient manufacturing technologies. Consequently, CoFRP manufacturing for automotive differs considerably from conventional CoFRP manufacturing for aerospace, particularly in terms of higher throughput with higher investment, but lower operating effort. Furthermore, automotive structures have smaller dimensions with more complex shapes, which makes it more challenging to avoid forming defects and to ensure complete injection. Since manufacturing makes the main difference between automotive and aerospace composite components, this feature article puts emphasis on the process technologies and on the corresponding material behavior and process simulation methods. For a holistic product design of automotive CoFRP components, a simultaneous virtual description and virtual optimization of both manufacturing process and structural capacity is necessary. Production effects must be considered in the part design and, thus, must be reliably predicted by process simulation as well as taken into account in subsequent simulation steps. This feature article therefore evaluates the current state of the art in the continuous virtual representation of CoFRP process chains, including the process steps forming, injection and curing. Furthermore, the integrated optimization along this CAE chain is a key factor for an economic part design and therefore another major subject of this article.

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Section: Analytical and Numerical Prediction Of Geometrical Deviationsmentioning

confidence: 93%

Fast processing and continuous simulation of automotive structural composite components

Henning

Kärger

Dörr

et al. 2019

Composites Science and Technology

120

View full text Add to dashboard Cite

show abstract

“…However, the structures subjected to the high temperature in above technologies or operations may experience substantial variations on the properties, resulting in residual stresses created in the structures. Residual stresses are self-balanced stresses that exist in the materials in the absence of any external forces or thermal loading and can initiate damage at interior, delamination at free edge or warpage of structures [5][6][7][8]. Hence the residual stresses may weaken the ability of bearing load leading to the degradation in the modulus and strength of structures.…”

Section: Introductionmentioning

confidence: 97%

A thermo-viscoelastic model of process-induced residual stresses in composite structures with considering thermal dependence

Ding

Sun

et al. 2016

Composite Structures

109

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“…In fact, shimming operations are involved with an increase of costs and product weight, when no contact exists between the matching surfaces. 4,5 This means that the gap formed by mating surfaces has to be filled by small sub-parts shaped according with the gap itself, since the high stiffness of the composite material makes post-moulding repair/reshaping of the deformed shapes difficult. Moreover, a high increase of the part internal stress may be involved by an assembly of deformed parts, thus deteriorating the part performance.…”

Section: Introductionmentioning

confidence: 99%

Two numerical tools for geometrical deviation management in composite assemblies: a comparison

Polini

Corrado

2020

Journal of Composite Materials

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The present work compares two numerical tools to predict the geometrical deviations of an assembly constituted by thin laminates in composite material. The first one is based on a virtual representation of both the manufacturing and the assembling processes, able to generate the variability meta-model for each component to be used in a skin-based assembly. The second one estimates the sensitivity matrix that connects the components’ variations to the assembly’s variations in the method of influence coefficients (MIC). They were experimentally verified on a case study. The comparison underlined the critical issue of both the tools.

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Manufacturing distortions of a CFRP box-structure – A semi-numerical prediction approach

Cited by 50 publications

References 9 publications

Fast processing and continuous simulation of automotive structural composite components

Fast processing and continuous simulation of automotive structural composite components

A thermo-viscoelastic model of process-induced residual stresses in composite structures with considering thermal dependence

Two numerical tools for geometrical deviation management in composite assemblies: a comparison

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