Top-hat crashboxes of thermoplastic fibre-metal-laminates processed in one-step thermoforming: Experimental and numerical study

Harhash, Mohamed; Fischer, Tobias; Grubenmann, Michael; Wei, Hua; Heingärtner, Jörg; Kuhtz, Moritz; Gude, Μaik; Hora, Pavel; Ziegmann, Gerhard

doi:10.1016/j.compositesb.2021.109367

Cited by 14 publications

(18 citation statements)

References 32 publications

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“…Moreover, the tensile behaviour of the RG core layer in the 45 • direction showed higher elongation at failure as well as reduced strength, mainly due to the fact that the fibres were more susceptible to shear deformation in the 45 • direction. This phenomenon has been described previously [28]. The soft core PA6 has a 200% elongation at failure and a tensile strength of 73 MPa, showing rather good formability.…”

Section: Materials and Sandwich Productionsupporting

confidence: 80%

“…Fla sandwich panels were prepared for the following deep drawing test, for which the influence of the different coefficients of thermal expansion of the mono-materials on the shrinkage was ignored. The relevant results for sandwich panel production via the hot press and the analysis on its structural properties via a top-hat profile were published in the previous study [28].…”

Section: Materials and Sandwich Productionmentioning

confidence: 99%

“…The strain at the punch edge shifted to the ε 2 = 0 direction after a transient evolution along the ε 2 = 0.5ε 1 direction due to the stress concentration and necking of the cover steel sheet along the warp and weft directions of RG. Another difference is that the strain evolution in the flange area was also directional, with the strain evolution along the 45 • direction being higher than that in the 0 • and 90 • directions, due to the fact that the core layer was prone to shear deformation in the 45 • direction [28,42]. Moreover, the strain evolution of the outer steel sheet of FML already exceeded its corresponding FLC level (solid red line in Figure 14b) at RT, indicating the cracking of the steel.…”

Section: Deep Drawing Of the Fmlmentioning

confidence: 99%

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Deep Drawing Behaviour of Steel–Glass Fibre-Reinforced and Non-Reinforced Polyamide–Steel Sandwich Materials

et al. 2023

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Thermoplastic-based fibre metal laminates (FMLs) have gained increasing interest in the automotive industry due to their forming potential—especially at higher temperatures—into complex components compared to thermoset-based ones. However, several challenges arise while processing thermoplastic-based FMLs. One the one hand, forming at room temperature (RT) leads to early failure modes, e.g., fracture and delamination. On the other hand, warm forming can extend their forming limits, although further defects arise, such as severe thickness irregularities and wrinkling problems. Therefore, this study focuses on developing different approaches for deep drawing conditions to deliver a promising, feasible, and cost-effective method for deep-drawn FML parts. We also describe the defects experimentally and numerically via the finite element method (FEM). The FMLs based on steel/glass fibre-reinforced polyamide 6 (GF-PA6/steel) are studied under different deep drawing conditions (temperatures, punch, and die dimensions). In addition, mono-materials and sandwich materials without fibre reinforcement are investigated as benchmarks. The results showed that the best deep drawing condition was at a temperature of 200 °C and a die/punch radius ratio of 0.67, with a gap/thickness ratio of ≤2.0. The FEM simulation via Abaqus 6.14 was able to successfully replicate the anisotropic properties and wrinkling of the GF-PA6 core in an FML, resembling the experimental results.

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Section: Materials and Sandwich Productionsupporting

confidence: 80%

Section: Materials and Sandwich Productionmentioning

confidence: 99%

Section: Deep Drawing Of the Fmlmentioning

confidence: 99%

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Deep Drawing Behaviour of Steel–Glass Fibre-Reinforced and Non-Reinforced Polyamide–Steel Sandwich Materials

et al. 2023

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“…The general methodology for this technique, along with its application in the automotive sector, can be seen in Figure 3. This technique generally requires the application of pressure and heat to join prepared metal skins to polymeric cores using adhesive layers [8,14,30,31]. The curing of the adhesive layer at the interlayer provides the adhesion strength in the MPM SMs [25].…”

Section: Adhesive Bondingmentioning

confidence: 99%

Precepts for Designing Sandwich Materials

Nayak,

Palkowski,

Carradò

2024

JETA

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The demand for innovative materials has been a significant driving force in material development in a variety of industries, including automotive, structural, and biomedical. Even though a tremendous amount of research has already been conducted on metallic, polymeric, and ceramic materials, they all have distinct drawbacks when used as mono-materials. This gave rise to the development of nature-inspired sandwich-structured composite materials. The combination of strong metallic skins with soft polymeric cores provides several advantages over mono-materials in terms of weight, damping, and mechanical property tuning. With this in mind, this review focuses on the various aspects of MPM SMs (Metal/polymer/metal Sandwich Materials). The reasons for the improved qualities of MPM SMs have been discussed, as well as the numerous approaches to producing such SMs. This review shows the various possibilities of achieving such SMs in complicated forms via different shaping techniques and intends to highlight the properties of MPM SMs’ remarkable qualities, the current trend in this field, and their potential to meet the demands of many industries.

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“…[9,10] In recent years, thermoplastic fiber metal laminates (TP-FMLs) have been developed to overcome the shortcomings of thermosetting FMLs. They provide properties of high modulus, high toughness, a nocured chemical reaction, short forming time and reprocessability, [11][12][13][14] and are thus suitable for rapid prototyping of large-scale structural and complex parts by stamping, deep drawing, and other processes. [15][16][17] However, the high molding temperature of TP-FMLs leads to long heating and thermoforming cycles, large thermal inertia, and large energy consumption during heating.…”

Section: Introductionmentioning

confidence: 99%

Self‐resistance heating forming and performance analysis of Al/PEEK/CFRP laminates

Zhang

Lü

et al. 2022

Polymer Composites

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To shorten the preparation cycle of Al/PEEK/CFRP laminates fabricated by Al sheets, peek films, and CFRP prepreg and reduce energy consumption during the preparation process to ensure the highest quality laminates, a novel forming process based on self-resistance electric (SRE) heating was proposed. Considering the tensile properties, fracture morphology, and void content comprehensively, the influence of current intensity (11.5, 12.5, 13.5 A) on the forming quality of laminates was explored. This optimized electric heating process was compared with the traditional heating process with respect to forming time, energy consumption, and the performance of the prepared samples. The results show that when the current is 12.5 A, the molding quality of the samples prepared by the SRE process is better than that of the traditional process.In addition, the SRE process significantly reduces forming times and saves energy. This SRE heating method provides a new process optimization pathway for the preparation and formation of fiber metal laminates and exhibits great prospects for future research.

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Top-hat crashboxes of thermoplastic fibre-metal-laminates processed in one-step thermoforming: Experimental and numerical study

Cited by 14 publications

References 32 publications

Deep Drawing Behaviour of Steel–Glass Fibre-Reinforced and Non-Reinforced Polyamide–Steel Sandwich Materials

Deep Drawing Behaviour of Steel–Glass Fibre-Reinforced and Non-Reinforced Polyamide–Steel Sandwich Materials

Precepts for Designing Sandwich Materials

Self‐resistance heating forming and performance analysis of Al/PEEK/CFRP laminates

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