Fast processing and continuous simulation of automotive structural composite components

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 art...

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Bibliographic Details
Published in:Composites science and technology Vol. 171; pp. 261 - 279
Main Authors: Henning, Frank, Kärger, Luise, Dörr, Dominik, Schirmaier, Fabian J., Seuffert, Julian, Bernath, Alexander
Format: Journal Article
Language:English
Published: Barking Elsevier Ltd 08.02.2019
Elsevier BV
Subjects:
Aerospace industry
Aircraft components
Automotive bodies
Automotive composites
Automotive engineering
Automotive parts
CAD
CAE chain
Computer aided design
Continuous fiber composites
Curing
Fiber composites
Fiber reinforced plastics
Forming
Injection
Mass production
Molding
Optimization
Polymers
Process chain
Process management
Process simulation
Product design
Reinforced plastics
RTM
Simulation
Tape
Weight reduction
Automotive composites
Process chain
Molding
Tape
Curing
Forming
RTM
CAE chain
Injection
Process simulation
ISSN:0266-3538, 1879-1050
Online Access:Get full text
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Summary: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.
Bibliography:SourceType-Scholarly Journals-1
ObjectType-Feature-1
content type line 14
ISSN:0266-3538
1879-1050
DOI:10.1016/j.compscitech.2018.12.007