Project Details
Projekt
Intrinsic production of hybrid components utilizing a modified RTM-process
Applicants
Professor Dr.-Ing. Rolf Mahnken; Professor Dr.-Ing. Gerson Meschut; Professor Dr.-Ing. Mirko Schaper; Professor Dr. Thomas Tröster
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Materials in Sintering Processes and Generative Manufacturing Processes
Materials in Sintering Processes and Generative Manufacturing Processes
Term
from 2014 to 2020
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 255986779
The main objective of the research project is to transfer the developed concept of an intrinsic manufacturing process from the first funding period (FP 1) to complex structures, real loading conditions and large-scale production. An internally reinforced B-pillar as well as an externally reinforced transmission tunnel are considered as demonstrators.In order to ensure a complete impregnation of the preform at elevated temperatures and to reduce the cycle times, the injection pressure has to be increased. Of great importance is the realization of a homogeneous interface layer. This layer acts as the load transmission element and thus mainly influences the overall function of the hybrid structures. Furthermore, the different heating of the metal and FRP side, developed during the first FP to reduce residual stresses, will be transferred to complex geometries. In addition, a self-sealing tool concept, which compensates for component tolerances and allows to replace the liable to wear silicon sealing will be studied. Finally, the splay stud concept, which is pursued in FP 1, is to be extended to 3D structures. For this purpose, a flexible anchoring mechanism has to be developed, a reduction of the interference contour has to be ensured, a suitable surface pretreatment has to be selected and additional tool kinematics have to be tested.In the field of materials science the laser structuring used in the FP 1 to achieve improved adhesion is not feasible for 3D geometries. For the forming of previously structured metal sheets a deformation-resistant structuring has to be developed. Moreover, non-orthogonal irradiation of the laser beam results in uneven structuring, which has to be avoided. Furthermore, in FP 1 a dependency between the laser and the loading direction was found, so that a load-adjusted structuring should be investigated. The cyclic and crash loadings and aging of the 3D hybrid structures, that should be examined in FP 2, cause complex failure mechanisms. Therefore suitable test methods have to be developed. Those are used to characterize the materials and to identify characteristic values for the simulation.The process development is based on the description of the process steps by experimentally well-founded modeling and simulation. For the macroscopic determination of the flow front during the form filling of complex hybrid components a coupling of curing and flow behavior is aimed. The influence of real loading conditions is very important for the component design. This influence will be described by the simulation of the aging of the matrix instead of the aging of the hybrid component. In order to simulate the crash behavior of the hybrid structure under the influence of aging, homogenization methods are developed. In addition the aging is coupled with the failure mechanisms.
DFG Programme
Priority Programmes
