Planning and optimisation of manufacturing process chains for functionally graded components—part 2: case study on self-reinforced thermoplastic composites

Abstract

In this sequel paper, the previously presented framework for the planning and optimisation of functionally graded components Biermann et al. (Prod Eng Res Dev 7(6):657-664, 2013) is applied within a case study. In addition to the application, the implementational infrastructure of the framework is provided and the preliminaries for applying the framework to the respective production system are presented. Hence, the practical realisation of the models and methods is documented. In the context of the case study, each step of the planning process is demonstrated in a visually assisted way. These visualisations are based on the specific steps of the wizard guiding the planner through the framework. As a central contribution, the specification of a non-trivial gradation and the planning of the corresponding process chain by means of the planning framework are demonstrated.

Modification of self-reinforced composites (SRCs) via film stacking process

“…Modification via films can essentially be performed using simple tool technology, thus resulting in a high level of process reliability. Comparable concepts for implementing locally different mechanical properties have so far always required a high level of process control (Biermann et al 2015;Paßmann 2009;Ries 2015). The possibility of generating locally differing mechanical properties can thus be exploited more easily in future in order to guarantee specific occupant protection, for example.…”

Investigation of the adhesive strength in a combined compaction and back-injection process to produce back-injected self-reinforced composites (SRCs)

“…It is common practice to manufacture semi-finished products as sheets, which are then formed into three-dimensional components in pressing processes. Automation of these processes has been taken forward in recent years in order to improve economic efficiency (Biermann et al 2012(Biermann et al , 2015Friedrich 2017;Heim et al 2012;Ries 2015;Rohde et al 2014;Zimnol et al 2012). By integrating continuous fibre-reinforced plastics in injection molding, their good mechanical properties can be combined with the freedom of design offered by injection molding.…”

Ultrasonic welding of all‐polypropylene composites

“…Plastics can be joined with several methods, ranging from snap fits through adhesive bonding to welding processes . Ultrasonic welding is one of the most frequently used welding technologies, especially in the electric, electronic and automotive industries .…”