book of abstracts - dem · this book of abstracts collects the works presented at the conference,...

BOOK OF ABSTRACTSINCLUDING PROGRAMME

EDITED BY:Ahmed Elmarakbi and Aurélio Araújo

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International Conference on Automotive CompositesICAutoC 2016

International Conference on Automotive Composites

21-23 September 2016, Hotel Holiday Inn, Lisbon, Portugal

Title:

BOOK OF ABSTRACTS of the International Conference on Automotive Composites 2016

Editors:

Ahmed Elmarakbi and Aurélio Araújo

Organizers:

• Institute of Mechanical Engineering (IDMEC), Portugal

• University de Sunderland, UK

Institutional Support:

CML- Câmara Municipal de LisboaTurismo de Lisboa

Graphic Design:

Luís Barros([email protected])

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WELCOME MESSAGE

Welcome MessageOn behalf of the ICAutoC 2016 organizing committee we are pleased to welcome you to Lisboa for the International Conference on Automotive Composites.

ICAutoC 2016 is the first international conference on automotive composites that aims to bring together and to disseminate knowledge between academics/researchers and industry practitioners. It will be a forum for engineers and applied scientists engaged in composite materials within automotive vehicles to contribute to the field and to disseminate technical information.

ICAutoC 2016 focuses on advanced composites (FRPs, reinforced thermoplastics, carbon-based composites and many others) and how they are designed, processed and utilized in automotive vehicles. It will include technical sessions on advanced composites in vehicle design/analysis and intends to cover all phases of composites design, analysis, modelling, testing, manufacturing and failure analysis. It is also expected to shed light on the performance of existing composites and future developments in automotive materials technology. The term, ‘automotive’, includes passenger cars, sport utility vehicles, vans, trucks, buses and recreational vehicles.

We want to express our appreciation to the authors and participants for their contributions, to all members of the committees involved in the preparation of this conference and to all the staff, with a special note of recognition to Ms. Paula Jorge for her invaluable contribution in all aspects related to the preparation of the conference.

This Book of Abstracts collects the works presented at the conference, as well as the programme and other pertinent information. Altogether, more than 50 lectures are presented, including 6 plenary lectures and a special session, reflecting the current state of the art in research and advances in the field of automotive composites. The proceedings of ICAutoC 2016, which include the full papers, are available to all participants in a flash disk distributed at the registration desk.

We sincerely hope that this conference will help providing an insight into the latest developments and future trends in automotive composites and that many subsequent editions will follow.

Lisboa, September 2016

Ahmed ElmarakbiAurélio Araújo

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ORGAnIzInG COMMITTEEAhmed ElmarakbiUniversity of Sunderland, UKEditor in Chief of International Journal of Automotive Composites

Aurélio AraújoUniversity of Lisbon, Portugal

Luís SousaUniversity of Lisbon, Portugal

Luís ReisUniversity of Lisbon, Portugal

InTERnATIOnAL SCIEnTIFIC COMMITTEEAdali, Sarp (University of KwaZulu-Natal), South Africa

Ambrosio, Jorge (University of Lisbon), Portugal

Barton, David (University of Leeds), UK

Belingardi, Giovanni (Politecnico di Torino), Italy

Bertocchi, Francesco (Nanesa S.r.l.), Italy

Bonhomme, Jorge (Universidad de Oviedo), Spain

Boria, Simonetta (University of Camerino), Italy

De Prada Martin, Luis (CIDAUT Foundation), Spain

De-Luca, Julio-Cesar (IRT Jules Verne), France

Di Cesare, Laura (Adler Plastic SPA, Italy)

Dias, João (University of Lisbon), Portugal

Duarte, Isabel (University of Aveiro), Portugal

El-Hage, Hicham (LIU), Lebanon

El-Safty, Sherif (NIMS), Japan

Fan, Tongxiang (Shanghai Jiao Tong University), China

Ferreira, Antonio (University of Porto), Portugal

Fliegener, Sascha (Fraunhofer IWM), Germany

Freitas, Manuel (University of Lisbon), Portugal

Fuchs, Anton (Virtual Vehicle), Austria

Gao, Xin-Lin (Southern Methodist University), USA

Garcia, Denise (CTAG - Automotive Technology Centre of Galicia), Spain

Gutowski, Voytek (CSIRO, Commonwealth Scientific & Industrial Research Organisation), Australia

Hadavinia, Homayoun (Kingston University London), UK

Han, Xu (Hunan University), China

COMMITTEES

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Hargreaves, Ben (NetComposites), UK

Haufe, André (DYNAmore GmbH), Germany

Henning, Frank (Fraunhofer ICT), Germany

Holmkvist, Anders (Inxide), Sweden

Hu, Ning (Chongqing University), China

Infante, Virginia (University of Lisbon), Portugal

Innocente, Franco (Delta Tech S.p.A.) , Italy

Kan, Cing-Dao (Steve) (George Mason University), USA

Kasano, Hideaki (Takushoku University), Japan

Keller, Thomas (École Polytechnique Fédérale de Lausanne), Switzerland

Kim, Jang-Kyo (Hong Kong University of Science & Technology, Hong Kong SAR), China

Lauter, Christian (University of Paderborn), Germany

Lee, Dai Gil (KAIST), Korea

Liew, Kim Meow (City University of Hong Kong, Hong Kong SAR), China

Lindsey, Kevin (FAR Composites), UK

Lukaszewicz, Dirk (BMW Group), Germany

Martorana, Brunetto (Centro Ricerche Fiat S.C.p.A), Italy

Miranda Guedes, J. (University of Lisbon), Portugal

Moleiro, Filipa (IDMEC), Portugal

Mota Soares, C.A. (IDMEC), Portugal

Mota Soares, C.M. (University of Lisbon), Portugal

Reddy, J.N (Texas A&M University), USA

Rodrigues, Helder (University of Lisbon), Portugal

Serry, Mohamed (The American University in Cairo), Egypt

Shahwan, Khaled W. (Fiat Chrysler Automobiles (FCA), USA

Silberschmidt, Vadim (Loughborough University), UK

Silva, Arlindo (Singapore University of Technology and Design), Singapore

Sousa, Luís (University of Lisbon), Portugal

Suleman, Afzal (IDMEC/IST), Portugal and (Univ. Victoria), Canada

Tabiei, Ala (University of Cincinnati), USA

Teixeira de Freitas, Sofia (TU Delft), Netherlands

Tita, Volnei (University of Sao Paulo - USP), Brazil

Torres Marques, António (University of Porto), Portugal

van Harmelen, Toon (TNO), Holland

Reis, Luis (University of Lisbon), Portugal

Vesenjak, Matej (University of Maribor), Slovenia

Villaro Ábalos, Elvira (InterQuimica), Spain

COMMITTEES

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GEnERAL InFORMATIOn

How to get to ICAutoC2016

Local: Hotel Holiday Inn, Lisbon, Portugal

Address: Av. António José de Almeida, 28A

Metro station: Saldanha

Carris bus (Saldanha): 736, 726, 727, 732, 738, 742, 745

Carris bus (Arco do Cego): 713, 797, 716

www.metrolisboa.pt

www.carris.pt

City Hall Welcome Reception:

A welcome reception will be offered by the City Hall, and will start at 18:30;

We suggest travelling downtown by subway (Green Line) from the Alameda to Baixa-Chiado station. The City Hall will be a 5m walk away from Baixa-Chiado station. Please do not forget to bring your Reception voucher.

Address: Camara Municipal de Lisboa, Praça do Município, 1149-014 Lisboa

BAIXA-CHIADO

PRAçA DO MunICÍPIO

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GEnERAL InFORMATIOn

OTHER INFORMATION:

INTERNET: lf you need internet connection please contact the secretariat.

LUNCHES: Will be held at the hotel restaurant

Conference Dinner Information:

The ICAutoC2016 conference dinner will be held at “Furnas do Guincho” Restaurant at 20:00.

The organization will provide transportation to and from the dinner venue. The bus will leave the conference venue at 19:00 and travelling along the costline to Cascais, where the restaurant is located offering a beautiful view over the sea. Please do not forget to bring your dinner voucher.

http://www.furnasdoguincho.pt/en/contacts/

CONFERENCE SECRETARIATMs. Paula JorgeIDMEC - Instituto Superior TécnicoAv. Rovisco Pais, 1049-001 Lisboa, PortugalEmail: [email protected]:+351 218 419 044Fax:+351 218 417 915

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AA - Automotive ApplicationsDOS - Design, Optimization and SimulationGHN - Green, Hybrid and New CompositesIDFF - Impact, Damage, Fatigue and Failure

MF - ManufacturingNC - NanocompositesPL - Plenary Lecture

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PROGRAMME

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PROGRAMME September 21

Tuesday, September 20

16:00 – 19:00 Registration

Wednesday, September 2108:00 – 08:45 Registration

08:45 – 09:00 Opening Ceremony (ROOM AÇORES)

SPECIAL LECTURE Chair: Simonetta Boria ROOM AÇORES

09:00 – 10:35 SPECIAL LECTURE OF THE EU GRAPHENE FLAGSHIP PROJECT-SPECIAL TASK ON AUTOMOTIVE COMPOSITES:GRAPHENE-BASED NANOCOMPOSITES FOR AUTOMOTIVEAhmed Elmarakbi, Brunetto Martorana, Francesco Bertocchi, Franco Innocente and Elvira Abalos

10:40 – 11:00 Coffee Break

SPECIAL LECTURE Chair: Simonetta Boria ROOM AÇORES

11:00 – 13:00 SPECIAL LECTURE OF THE EU GRAPHENE FLAGSHIP PROJECT-SPECIAL TASK ON AUTOMOTIVE COMPOSITES: GRAPHENE-BASED NANOCOMPOSITES FOR AUTOMOTIVEAhmed Elmarakbi, Brunetto Martorana, Francesco Bertocchi, Franco Innocente and Elvira Abalos

13:00 – 14:00 LUNCH

PLENARY LECTURE Chair: Brunetto Martorana ROOM AÇORES

14:00 – 14:45 FROM GRAPHENE TO CARBON FIBRES: MECHANICAL PROPERTIES AND STRESS TRANSFER IN COMPOSITESCostas Galiotis - FORTH/ ICE-HT; University of Patras, Greece

ROOM AÇORES(Chair: Amélia Loja)

ROOM PORTO SANTO(Chair: Isabel Duarte)

DOS IDesign, Optimization and Simulation I

GHN IGreen, Hybrid and new Composites I

14:50 – 15:10 ID02

DRAPE SIMULATION SUPPORTED DIFFERENTIAL DESIGN APPROACH FOR COST EFFICIENT COMPOSITE AUTOMOTIVE STRUCTURESPer Mårtensson, Dan Zenkert, Malin ÅkermoPresenting Author: Per Mårtensson

ID04

ALUMINUM HYBRID SQUARE TUBE BEAM REINFORCED BY A THIN GLASS-FIBER COMPOSITE SKIN LAYERNak-Sam Choi, Hyung-Jin KimPresenting Author: Nak-Sam Choi

15:10 – 15:30 ID021

ITERATIVE DETERMINATION OF THE TAILORING OF BLANKS FOR A WASTE-FREE COMPOSITE FORMING BY MEANS OF FINITE ELEMENT FORMING SIMULATIONDominik Dörr, Lukas Lipowsky, Fabian Schirmaier, Luise Kärger, Frank HenningPresenting Author: Dominik Dörr

ID011

InnOVATIVE BIO-BASED COMPOSITES FOR AuTOMOTIVE APPLICATIOnSAmparo Verdu, Rosa Gonzalez LeybaPresenting Author: Amparo Verdu

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15:30 – 15:50 ID023

METHODICAL DESIGN PROCESS FOR STRUCTURAL FRP SYSTEMSJonathan Schmidt, Benedikt Heuer, Anna-Lena Beger, Zhuzhell Montano, Hendrik Hoffmann, Jörg Feldhusen and Dave CadwellPresenting Author: Jonathan Schmidt

ID019

MECHANICAL PROPERTIES OF SELF REINFORCED POLYAMIDE BASED COMPOSITE SYSTEMS Paolo Vecchione, Domenico Acierno and Pietro RussoPresenting Author: Paolo Vecchione


ROOM AÇORES(Chair: Sascha Fliegener)

ROOM PORTO SANTO(Chair: Mihaela Mihai)

DOS IIDesign, Optimization and Simulation II

GHN IIGreen, Hybrid and new Composites II

16:10 – 16:30 ID60

TOWARDS THE CHARACTERIZATION OF BEHAVIOURAL UNCERTAINTY ON CFRP LAMINATESAmélia Loja, Alda Carvalho, Tiago Silva Presenting Author: Amélia Loja

ID62

CRUSH PERFORMANCE OF FOAM FILLED TUBES MADE OF ALUMINIUM ALLOYS AT DIFFERENT LOADING CONDITIONS Isabel Duarte, Matej Vesenja, Lovre Krstulović-OparaPresenting Author: Isabel Duarte

16:30 – 16:50 ID67

STRUCTURES WITH ACTIVEAND PASSIVE VIBRATION CONTROL: PARAMETER ESTIMATION OF VISCO-PIEZOELECTRIC MECHANICAL PROPERTIESVitor Carvalho, Aurélio Araújo and Jorge BelinhaPresenting Author: Vitor Carvalho

ID24

MECHANISM-BASED SPECIFIC DESIGN IMPROVES THE TENSILE BEHAVIOR OF HYBRID MATERIAL SYSTEMS CONSISTING OF DIFFERENT SHEET METALS David Hummelberger, Kay André Weidenmann, Luise Kärger, Frank HenningPresenting Author: David Hummelberger

16:50 – 17:10 ID05

ANALYSIS OF STACKING SEQUENCE EFFECTS OF THE ROTATING COMPOSITE SHAFTS USING A FINITE ELEMENT FORMULATIONSafa Ben Arab, José Dias Rodrigues, Slim Bouaziz, Mohamed HaddarPresenting Author: Safa Ben Arab

ID40

LOWER-COST, LIGTHER AND GREENER POLYPROPYLENE-BASED BIOCOMPOSITES FOR AUTOMOTIVE APPLICATIONS Mihaela Mihai, Karen Stoeffler Presenting Author: Mihaela Mihai

17:10 – 17:30 ID09

COMPREHENSIVE NUMERICAL SIMULATION OF HIGH PERFORMANCE SMC COMPRESSION Laura Oter Carbonell, Christophe Binetruy, Sebastien Comas Cardona and Christophe Aufrere Presenting Author: Laura Oter Carbonell

ID41

BIOCOMPOSITES AND BIOBLENDS BASED ON ENGINEERING THERMOPLASTICS FOR AUTOMOTIVE APPLICATIONS Mihaela Mihai, Karen Stoeffler Presenting Author: Karen Stoeffler

18:30 – 19:30 Welcome Reception at City Hall


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Thursday, September 22PLENARY LECTURES Chair: André Haufe ROOM AÇORES

09:00 – 09:45 SUPERCOMPOSITES FOR AUTOMOTIVENicola M. Pugno - University of Trento, Italy

09:50 – 10:35 CRASHWORTHINESS EVALUATION OF COMPOSITE VEHICLE STRUCTURAL COMPONENTS IN AUTOMOTIVE APPLICATIONSCing-Dao (Steve) Kan - George Mason University, USA


ROOM AÇORES(Chair: Jean-Pierre Delsemme)

ROOM PORTO SANTO(Chair: Luís Reis)

IDFF IImpact, Damage, Fatigue and Failure I

AAAutomotive Applications

11:00 – 11:20 ID01

IMPACT ENERGY EFFECTS ON THE DAMAGE BEHAVIOR OF GLASS FABRIC/RECYCLED POLYOLEFIN COMPOSITE LAMINATES Pietro Russo, Giorgio Simeoli, Antonio Langella, Ilaria Papa and Valentina LoprestoPresenting Author: Pietro Russo

ID37

INNOVATIVE AUTOMOTIVE CFRP CROSS LEAF SPRING Andrea Airale, Massimiliana Carello and Alessandro FerrarisPresenting Author: Andrea Airale

11:20 – 11:40 ID06

CRASHWORTHINESS DESIGN ISSUES FOR A LIGHTWEIGHT RACING CAR Simonetta BoriaPresenting Author: Simonetta Boria

ID43

ARE PLASTIC MATERIALS SUITABLE FOR ENGINE COMPONENTS? SOME POSSIBLE SOLUTIONSCristiana Delprete, Carlo RossoPresenting Author: Carlo Rosso

11:40 – 12:00 ID10

NEW METHOD TO GENERATE SUITABILITY ASSESSMENTS OF COMPOSITE-METAL-HYBRID MATERIAL SYSTEMS FOR AUTOMOTIVE CRASH STRUCTURESMichael Dlugosch, Jens Fritsch, Dirk Lukaszewicz and Stefan HiermaierPresenting Author: Michael Dlugosch

ID51

CARS: CARBOn FIBER REInFORCED STEEL FOR STRuCTuRAL AuTOMOTIVE APPLICATIOnSChristian Lauter, Julian Loeseke, Zheng Wang, Thomas TroesterPresenting Author: Zheng Wang

12:00 – 12:20 ID15

APPLICATIOn OF FIBRE REInFORCED PLASTIC SAnDWICH STRuCTuRES FOR AuTOMOTIVE CRASHWORTHInESSDirk Lukaszewicz, Lourens Blok, James Kratz, Carwyn Ward, Christos Kassapoglou Presenting Author: Dirk Lukaszewicz

ID54

NOVEL CERAMIC COMPOSITES FOR FIRE RETARDANT APPLICATIONS IN AUTOMOTIVE AND PUBLIC TRANSPORTATIONPatrick Weichand, Rainer Gadow, Miguel Jimenez MartinezPresenting Author: Miguel Jimenez Martinez

12:20 – 12:40 ID17

IN SITU TESTING AND MICROMECHANICAL SIMULATION OF FIBER REINFORCED THERMOPLASTICSSascha Fliegener, Tobias Kennerknecht, Matthias KabelPresenting Author: Sascha Fliegener

ID58

A COMPOSITE CHASSIS FOR A FORMULA STUDENT VEHICLELuis Sousa, Virgínia Infante, Ricardo FerreiraPresenting Author: Luis Sousa


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12:40 – 13:00 ID27

IN SITU TESTING AND MICROMECHANICAL SIMULATION OF FIBER REINFORCEDTHERMOPLASTICSShuhei Yasuda, Yuki Takagaki, Nobuyoshi Kajioka, Hiroaki Yamada, Yuqiu Yang, Tadashi Uozumi, Hiroyuki Hamada Presenting Author: Hiroyuki Hamada

ID35

PERFORMANCE OF A CARBON/CARBON COMPOSITE CLUTCH DURING FORMULA ONE RACE START CONDITIONSRanvir Kalare, Peter Brooks, David BartonPresenting Author: David Barton

13:00 – 14:00 Lunch

PLENARY LECTURES Chair: Nicola M. Pugno ROOM AÇORES

14:00 – 14:45 DEVELOPMENT OF THERMOSET COMPOSITE STRUCTURESFOR AUTOMOTIVE LIGHTWEIGHTINGFrank Henning - Fraunhofer ICT, Germany

ROOM AÇORES(Chair: Dirk Lukaszewicz)

ROOM PORTO SANTO(Chair: Luís Sousa)

IDFF IIImpact, Damage, Fatigue and Failure II

MF IManufacturing I

14:50 – 15:10 ID48

RESIDUAL ELASTIC PROPERTIESAND DAMAGE ASSESSMENTIN VEHICLE COMPONENTS MADEOF COMPOSITE MATERIALSAlessio D’Andrea, Davide Paolino,Giovanni Belingardi, Brunetto Martoranaand Vito LambertiniPresenting Author: Giovanni Belingardi

ID03

A NEWLY INJECTION MOLDING SYSTEM FOR SHORT FIBER COMPOSITESAkio Kataoka, Hirofumi Ichikawa, Akihiko Imajo, Hiroyuki Inoya and Hiroyuki Hamada Presenting Author: Akihiko Imajo

15:10 – 15:30 ID49

DAMAGE MODELING IN COMPOSITE MATERIAL, AN AUTOMOTIVE APPLICATIONJean-Pierre Delsemme, Michael Bruyneel and Cédric LequesnePresenting Author: Jean-Pierre Delsemme

ID12

ESTABLISHMENT OF CVT BELT MOLDINGTECHNIQUE MADE OF CARBON FIBER REINFORCED THERMOPLASTICS RESIN COMPOSITE MATERIALSTaichi Sugiura, Tatsuya Tanaka,Tsutao KatayamaPresenting Author: Taichi Sugiura

15:30 – 15:50 ID71

DESIGN OF A COMPOSITE CRASH BOX FOR A FORMULA STUDENT TEAM CAR: PRELIMINARY SIMULATIONSAND TESTINGAndré Santos, Aurélio Araújo, José Aguilar Madeira, Hernâni LopesPresenting Author: André Santos

ID14

TEMPERATURE DISTRIBUTIONIN THICKNESS DIRECTIONOF THERMOPLASTIC LAMINATESDURING THERMOFORMINGDaniel Kugele, Julius Rausch, Philipp Müller, Luise Kärger, Frank HenningPresenting Author: Daniel Kugele



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ROOM AÇORES(Chair: Per Mårtensson)

ROOM PORTO SANTO(Chair: Andrea Airale)

NC INanocomposites I

MF IIManufacturing II

16:10 – 16:30 ID36

MULTI SCALE MODELLING OF GRAPHENE PLATELETS REINFORCED POLYMER MATRIX COMPOSITE MATERIALSWiyao Azoti, Ahmed ElmarakbiPresenting Author: Wiyao Azoti

ID16

MANUFACTURING OF COMPLEX PARTS BASED ON UNIDIRECTIONAL TAPESRaquel Ledo, Vanessa VentosinosPresenting Author: Raquel Ledo

16:30 – 16:50 ID42

HIERARCHICAL MODELLING OF CARBON FIBRES GRAPHENE REINFORCED POLYMER COMPOSITES MATERIALSHicham El-Hage, Mustapha El Kady, Ahmed Elmarakbi, Wiyao AzotiPresenting Author: Hicham El-Hage

ID18

EXPERIMENTAL ANALYSIS OF THE INFLUENCE OF FOAM DENSITY AND SRFACE TREATMENT ON THE FAILURE BEHAVIOR OF POLYURETHANE FOAM DURING THE RTM PROCESSJens Gerstenkorn, Guenter Deinzer, Martin H. Kothmann, Felix Diebold, Luise Kaerger and Frank HenningPresenting Author: Jens Gerstenkorn

16:50 – 17:10 ID44

MECHANICAL PROPERITES OF A THERMOPLASTIC ADHESIVE MODIFIED WITH GRAPHENE NANOPLATELETS FOR AUTOMOTIVE APPLICATIONSRaffaele Ciardiello, Giovanni Belingardi, Brunetto Martorana, Francesco Cristiano, Francesco Bertocchi, Valentina Brunella, Marco ZanettiPresenting Author: Brunetto Martorana

ID22

A STRATEGY TO PRODUCE METAL-POLYMER HYBRID COMPONENTS BY ADDITIVE MANUFACTURING PROCESSESMiguel R. Silva, David S. Oliveira, Artur Mateus, Cândida MalçaPresenting Author: Miguel R. Silva

17:10 – 17:30 ID13

POLYPROPYLENE NANOCOMPOSITES WITH IMPROVED PROPERTIES FOR AUTOMOTIVE APPLICATIONSLuis De Prada, Manuel Herrero, Jose Maria Pastor BarajasPresenting Author: Luis De Prada

ID28

EFFECT OF FIBER LENGTH DISTRIBUTION ON MECHANICAL PROPERTIES OF COMPOSITES IN INJECTION MOLDING PLASTICIZATIONIssei Harima, Hiroaki Yamada, Nobuyoshi Kajioka, Yuqiu Yangand Hiroyuki HamadaPresenting Author: Issei Harima

17:30 – 17:50 ID065

RAPID, LOW ENERGY PROCESSING OF POLYMERS AND COMPOSITESTerry McGrail, Walter Stanley, Ananda Roy, Dipa RoyPresenting Author: Terry McGrail

20:00 – 23:00 Conference Dinner


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Friday, September 23PLENARY LECTURES Chair: Hicham El-Hage ROOM AÇORES

09:00 – 09:45 BODY STRUCTURE DESIGN STRATEGIES USING NEW COMPOSITE AND AL MATERIALS AND ENABLED TECHNOLOGIES (EVOLUTION FP7 FUNDED PROJECT)Elena Cischino - Pininfarina S.p.A., Italy

09:50 – 10:35 THE SIMULATION PROCESS CHAIN: FROM MANUFACTURING TO PART PERFORMANCE OF COMPOSITESAndré Haufe - DYNAmore GmbH, Germany


ROOM AÇORES(Chair: Wiyao Azoti)

ROOM PORTO SANTO(Chair: Aurélio Araújo)

NC IInanocomposites II

MF IIIManufacturing

11:00 – 11:20 ID46

MULTISCALE ANALISYS OF THE MECHANICAL PERFORMANCE IMPROVEMENT OF COMPOSITES CFRP LAMINATES, AND COMPOSITES WITH SHORT GLASS FIBERS, THROUGH THE ADDITION OF NANOPLATLETS OF GRAPHENEAhmed Elmarakbi, Matteo BassoPresenting Author: Matteo Basso

ID29

STUDY ON ADAPTATION OF RECYCLED CFRTP TO THE HYBRID INJECTION MOLDINGJunya Shiode, Tatsuya Tanaka, Masaya Kawashima, Masao Tomioka, Takeshi Ishikawa, Tatsuo KatayamaPresenting Author: Junya Shiode

11:20 – 11:40 ID50

THERMAL AND ELECTRICAL PROPERTIES OF GRAPHENE-BASED THERMOSET COMPOSITES: A STUDY ON THE ROLE OF GRAPHENE NANO-PLATELETS MORPHOLOGYNicola Mirotta, Alessandro Kovtun, Emanuele Treossi, Alberto Fina, Julio Gomez, Tamara Blanco and Vincenzo PalermoPresenting Author: Nicola Mirotta

ID31

APPLICATION OF AN INTEGRATED INJECTION APPROACH TO MANUFACTURING MULTIMATERIAL PRE-PREGS COMPONENTSDavid S. Oliveira, Artur Mateus, Miguel R. Silva and Cândida MalçaPresenting Author: David S. Oliveira

11:40 – 12:00 ID59

IMPROVEMENT OF INTERLAMINAR MECHANICAL PROPERTIES OF CFRP LAMINATES BASED ON NANOFILLER INTERFACE REINFORCEMENTNing Hu, Huiming Ning and Jianyu ZhangPresenting Author: Jianyu Zhang

ID33

INVESTIGATION OF MECHANICAL PROPERTIES OF A FIBER FAIR JOINING CONCEPT FOR FIBER REINFORCED THERMOPLASTICSChristian Brecher, Clemens Buschhoff, Henning JanssenPresenting Author: Clemens Buschhoff

12:00 – 12:20 ID53

IMPACT BEHAVIOUR OF PPA-GLASS FIBRE COMPOSITES AUTOMOTIVE COMPONENTSLaura Gendre, Ian Butterworth, Tony RidlerPresenting Author: Laura Gendre

12:20 – 12:40 ID34

SEMI-SOLID JOINING OF ALUMINIUM AND CARBON FABRICLukas Marx, Mathias LiewaldPresenting Author: Lukas Marx

12:40 Closing Session + Lunch


15

International Conference on Automotive Composites ICAutoC 2016

ABSTRACTS

17


COnTEnTSPL - PLEnARY LECTuRESL GRAPHENE-BASED NANOCOMPOISTES FOR AUTOMOTIVE 23

Ahmed Elmarakbi, Brunetto Martorana, Francesco Bertocchi, Franco Innocente and Elvira Abalos

PL 1 FROM GRAPHENE TO CARBON FIBRES: MECHANICAL PROPERTIES AND STRESS TRANSFER IN COMPOSITES

24

Costas Galiotis

PL 2 SUPERCOMPOSITES FOR AUTOMOTIVE 25Nicola M. Pugno

PL 3 CRASHWORTHINESS EVALUATION OF COMPOSITE VEHICLE STRUCTURAL COMPONENTS IN AUTOMOTIVE APPLICATIONS

26

Cing-Dao (Steve) Kan

PL 4 DEVELOPMENT OF THERMOSET COMPOSITE STRUCTURES FOR AUTOMOTIVE LIGHTWEIGHTING

27

Frank Henning, Philipp Rosenberg

PL 5 EVOLUTION FP7 FUNDED PROJECT - BODY STRUCTURE DESIGN STRATEGIES USING NEW COMPOSITE AND ALUMINUM MATERIALS AND ENABLED TECHNOLOGIES

28

Elena Cischino, Cristina Elizetxea, Iratxe Lopez, Zina Vuluga, Mikelis Kirpluks, Peteris Cabulis, Jesper Christiansen, Catalina-Gabriela Sanporean, John Deverill, Francesca Di Paolo, César Maestro, Estibaliz Alcalde and Enrico Mangino

PL 6 THE SIMULATION PROCESS CHAIN: FROM MANUFACTURING TO PART PERFORMANCE OF COMPOSITES

29

André Haufe, Christian Liebold

AA - AuTOMOTIVE APPLICATIOnSID 35 PERFORMANCE OF A CARBON/CARBON COMPOSITE CLUTCH DURING FORMULA ONE RACE

START CONDITIONS33

Ranvir Kalare, Peter Brooks and David Barton

ID 37 INNOVATIVE AUTOMOTIVE CFRP CROSS LEAF SPRING 34Andrea Airale, Massimiliana Carello and Alessandro Ferraris

ID 43 ARE PLASTIC MATERIALS SUITABLE FOR ENGINE COMPONENTS? SOME POSSIBLE SOLUTIONS 35Cristiana Delprete and Carlo Rosso

ID 51 CARS: CARBON FIBER REINFORCED STEEL FOR STRUCTURAL AUTOMOTIVE APPLICATIONS 36Christian Lauter, Julian Loeseke, Zheng Wang and Thomas Troester

ID 54 NOVEL CERAMIC COMPOSITES FOR FIRE RETARDANT APPLICATIONS IN AUTOMOTIVE AND PUBLIC TRANSPORTATION

37

Patrick Weichand, Rainer Gadow and Miguel Jimenez Martinez

ID 58 A COMPOSITE CHASSIS FOR A FORMULA STUDENT VEHICLE 38Luis Sousa, Virgínia Infante and Ricardo Ferreira

DOS - DESIGn, OPTIMIzATIOn AnD SIMuLATIOnID 2 DRAPE SIMULATION SUPPORTED DIFFERENTIAL DESIGN APPROACH FOR COST EFFICIENT

COMPOSITE AUTOMOTIVE STRUCTURES41

Per Mårtensson, Dan Zenkert and Malin Åkermo

18


ID 5 ANALYSIS OF STACKING SEQUENCE EFFECTS OF THE ROTATING COMPOSITE SHAFTS USINGA FINITE ELEMENT FORMULATION

42

Safa Ben Arab, José Dias Rodrigues, Slim Bouaziz and Mohamed Haddar

ID 9 COMPREHENSIVE NUMERICAL SIMULATION OF HIGH PERFORMANCE SMC COMPRESION. 43Laura Oter Carbonell, Christophe Binetruy, Sebastien Comas Cardona and Christophe Aufrere

ID 21 ITERATIVE DETERMINATION OF THE TAILORING OF BLANKS FOR A WASTE-FREE COMPOSITE FORMING BY MEANS OF FINITE ELEMENT FORMING SIMULATION

44

Dominik Dörr, Lukas Lipowsky, Fabian Schirmaier, Luise Kärger and Frank Henning

ID 23 METHODICAL DESIGN PROCESS FOR STRUCTURAL FRP SYSTEMS 45Jonathan Schmidt, Benedikt Heuer, Anna-Lena Beger, Zhuzhell Montano, Hendrik Hoffmann, Jörg Feldhusen and Dave Cadwell

ID 60 TOWARDS THE CHARACTERIZATION OF BEHAVIOURAL UNCERTAINTY ON CFRP LAMINATES 46Amélia Loja, Alda Carvalho and Tiago Silva

ID 67 STRUCTURES WITH ACTIVE AND PASSIVE VIBRATION CONTROL: PARAMETER ESTIMATION OF VISCO-PIEZOELECTRIC MECHANICAL PROPERTIES

47

Vitor Carvalho, Aurélio Araújo and Jorge Belinha

GHn - GREEn, HYBRID AnD nEW COMPOSITESID 4 ALUMINUM HYBRID SQUARE TUBE BEAM REINFORCED BY A THIN GLASS-FIBER COMPOSITE

SKIN LAYER51

Nak-Sam Choi and Hyung-Jin Kim

ID 11 INNOVATIVE BIO-BASED COMPOSITES FOR AUTOMOTIVE APPLICATIONS 52Amparo Verdu and Rosa Gonzalez Leyba

ID 19 MECHANICAL PROPERTIES OF SELF REINFORCED POLYAMIDE BASED COMPOSITE SYSTEMS 53Paolo Vecchione, Domenico Acierno and Pietro Russo

ID 24 MECHANISM-BASED SPECIFIC DESIGN IMPROVES THE TENSILE BEHAVIOR OF HYBRID MATERIAL SYSTEMS CONSISTING OF DIFFERENT SHEET METALS

54

David Hummelberger, Kay André Weidenmann, Luise Kärger and Frank Henning

ID 40 LOWER COST, LOWER WEIGHT, AND GREENER POLYPROPYLENE BIOCOMPOSITES FOR AUTOMOTIVE APPLICATIONS

55

Mihaela Mihai and Karen Stoeffler

ID 41 BIOCOMPOSITES AND BIOBLENDS BASED ON ENGINEERING THERMOPLASTICS FOR AUTOMOTIVE APPLICATIONS

56

Mihaela Mihai and Karen Stoeffler

ID 62 CRUSH PERFORMANCE OF FOAM FILLED TUBES MADE OF ALUMINIUM ALLOYS AT DIFFERENT LOADING CONDITIONS

57

Isabel Duarte, Matej Vesenjak and Lovre Krstulović-Opara

IDFF - IMPACT, DAMAGE, FATIGuE AnD FAILuREID 1 IMPACT ENERGY EFFECTS ON THE DAMAGE BEHAVIOR OF GLASS FABRIC/RECYCLED

POLYOLEFIN COMPOSITE LAMINATES61

Pietro Russo, Giorgio Simeoli, Antonio Langella, Ilaria Papa and Valentina Lopresto

ID 6 CRASHWORTHINESS DESIGN ISSUES FOR A LIGHTWEIGHT RACING CAR 62Simonetta Boria

19


ID 10 NEW METHOD TO GENERATE SUITABILITY ASSESSMENTS OF COMPOSITE-METAL-HYBRID MATERIAL SYSTEMS FOR AUTOMOTIVE CRASH STRUCTURES

63

Michael Dlugosch, Jens Fritsch, Dirk Lukaszewicz and Stefan Hiermaier

ID 15 APPLICATION OF FIBRE REINFORCED PLASTIC SANDWICH STRUCTURES FOR AUTOMOTIVE CRASHWORTHINESS

64

Dirk Lukaszewicz, Lourens Blok, James Kratz, Carwyn Ward and Christos Kassapoglou

ID 17 IN SITU TESTING AND MICROMECHANICAL SIMULATION OF FIBER REINFORCED THERMOPLASTICS

65

Sascha Fliegener, Tobias Kennerknecht and Matthias Kabel

ID 27 ENERGY ABSORPTION PROPERTIES OF BRAIDED COMPOSITE RODS 66Shuhei Yasuda, Yuki Takagaki, Nobuyoshi Kajioka, Hiroaki Yamada, Yuqiu Yang, Tadashi Uozumi and Hiroyuki Hamada

ID 48 RESIDUAL ELASTIC PROPERTIES AND DAMAGE ASSESSMENT IN VEHICLE COMPONENTS MADE OF COMPOSITE MATERIALS

67

Alessio D’Andrea, Davide Paolino, Giovanni Belingardi, Brunetto Martorana and Vito Lambertini

ID 49 DAMAGE MODELING IN COMPOSITE MATERIAL, AN AUTOMOTIVE APPLICATION. 68Jean-Pierre Delsemme, Michael Bruyneel and Cédric Lequesne

ID 71 DESIGN OF A COMPOSITE CRASH BOX FOR A FORMULA STUDENT TEAM CAR:PRELIMINARY SIMULATIONS AND TESTING

69

André Santos, Aurelio Araujo, José Aguilar Madeira and Hernâni Lopes

MF - MAnuFACTuRInGID 3 A NEWLY INJECTION MOLDING SYSTEM FOR SHORT FIBER COMPOSITES 73

Akio Kataoka, Hirofumi Ichikawa, Akihiko Imajo, Hiroyuki Inoya and Hiroyuki Hamada

ID 12 ESTABLISHMENT OF CVT BELT MOLDING TECHNIQUE MADE OF CARBON FIBER REINFORCED THERMOPLASTICS RESIN COMPOSITE MATERIALS

74

Taichi Sugiura, Tatsuya Tanaka and Tsutao Katayama

ID 14 TEMPERATURE DISTRIBUTION IN THICKNESS DIRECTION OF THERMOPLASTIC LAMINATES DURING THERMOFORMING

75

Daniel Kugele, Julius Rausch, Philipp Müller, Luise Kärger and Frank Henning

ID 16 MANUFACTURING OF COMPLEX PARTS BASED ON UNIDIRECTIONAL TAPES 76Raquel Ledo and Vanessa Ventosinos

ID 18 EXPERIMENTAL ANALYSIS OF THE INFLUENCE OF FOAM DENSITY AND SURFACE TREATMENT ON THE FAILURE BEHAVIOR OF POLYURETHANE FOAM DURING THE RTM PROCESS

77

Jens Gerstenkorn, Guenter Deinzer, Martin H. Kothmann, Felix Diebold, Luise Kaerger and Frank Henning

ID 22 A STRATEGY TO PRODUCE METAL-POLYMER HYBRID COMPONENTS BY ADDITIVE MANUFACTURING PROCESSES

78

Miguel R. Silva, David S. Oliveira, Artur Mateus and Cândida Malça

ID 28 EFFECT OF FIBER LENGTH DISTRIBUTION ON MECHANICAL PROPERTIES OF COMPOSITES IN INJECTION MOLDING PLASTICIZATION

79

Issei Harima, Hiroaki Yamada, Nobuyoshi Kajioka, Yuqiu Yang and Hiroyuki Hamada

ID 29 STUDY ON ADAPTATION OF RECYCLED CFRTP TO THE HYBRID INJECTION MOLDING 80Junya Shiode, Tatsuya Tanaka, Masaya Kawashima, Masao Tomioka, Takeshi Ishikawa and Tatsuo Katayama

20

ID 31 APPLICATION OF AN INTEGRATED INJECTION APPROACH TO MANUFACTURING MULTIMATERIAL PRE-PREGS COMPONENTS

81

David S. Oliveira, Artur Mateus, Miguel R. Silva and Cândida Malça

ID 33 INVESTIGATION OF MECHANICAL PROPERTIES OF A FIBER FAIR JOINING CONCEPT FOR FIBER REINFORCED THERMOPLASTICS

82

Christian Brecher, Clemens Buschhoff and Henning Janssen

ID 34 SEMI-SOLID JOINING OF ALUMINIUM AND CARBON FABRIC 83Lukas Marx and Mathias Liewald

ID 53 IMPACT BEHAVIOUR OF PPA-GLASS FIBRE COMPOSITES AUTOMOTIVE COMPONENTS 84Laura Gendre, Ian Butterworth and Tony Ridler

ID 65 RAPID, LOW ENERGY PROCESSING OF POLYMERS AND COMPOSITES 85Terry McGrail, Walter Stanley, Ananda Roy and Dipa Roy

nC - nAnOCOMPOSITESID 13 POLYPROPYLENE NANOCOMPOSITES WITH IMPROVED PROPERTIES

FOR AUTOMOTIVE APPLICATIONS89

Luis De Prada, Manuel Herrero and Jose Maria Pastor Barajas

ID 36 MULTI SCALE MODELLING OF GRAPHENE PLATELETS REINFORCED POLYMER MATRIX COMPOSITE MATERIALS

90

Wiyao Azoti and Ahmed Elmarakbi

ID 42 HIERARCHICAL MODELLING OF CARBON FIBRES GRAPHENE REINFORCED POLYMER COMPOSITES MATERIALS

91

Hicham El-Hage, Mustapha El Kady, Ahmed Elmarakbi and Wiyao Azoti

ID 44 MECHANICAL PROPERITES OF A THERMOPLASTIC ADHESIVE MODIFIED WITH GRAPHENE NANOPLATELETS FOR AUTOMOTIVE APPLICATIONS.

92

Raffaele Ciardiello, Giovanni Belingardi, Brunetto Martorana, Francesco Cristiano, Francesco Bertocchi, Valentina Brunella and Marco Zanetti

ID 46 MULTISCALE ANALISYS OF THE MECHANICAL PERFORMANCE IMPROVEMENT OF COMPOSITES CFRP LAMINATES, AND COMPOSITES WITH SHORT GLASS FIBERS, THROUGH THE ADDITION OF NANOPLATLETS OF GRAPHENE

93

Ahmed Elmarakbi and Matteo Basso

ID 50 THERMAL AND ELECTRICAL PROPERTIES OF GRAPHENE-BASED THERMOSET COMPOSITES:A STUDY ON THE ROLE OF GRAPHENE NANO-PLATELETS MORPHOLOGY

94

Nicola Mirotta, Alessandro Kovtun, Emanuele Treossi, Alberto Fina, Julio Gomez, Tamara Blanco and Vincenzo Palermo

ID 59 IMPROVEMENT OF INTERLAMINAR MECHANICAL PROPERTIES OF CFRP LAMINATES BASEDON NANOFILLER INTERFACE REINFORCEMENT

95

Ning Hu, Huiming Ning and Jianyu Zhang


21


PLPLENARY LECTURES

23


SPECIAL LECTURE

GRAPHEnE-BASED nAnOCOMPOISTES FOR AuTOMOTIVE

Ahmed Elmarakbi(1), Brunetto Martorana(2), Francesco Bertocchi(3), Franco Innocente(4), Elvira Abalos(5)

(1)University of Sunderland, United [email protected]

(2)CRF Fiat, [email protected]

(3)Nanesa S.r.l., [email protected]

(4)Delta Tech S.p.A., [email protected]

(5)InterQuimica, [email protected]

KEywORDS: Automotive applications, Composite modelling and design, Energy efficient and safe vehicles, Graphene, Graphene composites

SUmmaRy: The present initiative provides a summary overview on Graphene Related materials (GRM) for automotive applications and investigates efficient ways to integrate Graphene as polymer reinforcements within composite materials for energy-efficient and safe vehicles (EESVs). An approa-ch that starts from the nano-scale through the Graphene elaboration by experiments to meso/macro--scale by continuum mechanics modelling is discussed with respect to some limiting factors in terms of the large scale production, the interfacial behaviour, the amount of wrinkling and network structure. Finally, a strategy for modelling such a composite is elaborated in the framework of the Graphene Flagship to well understand such limitations for a full applicability of Graphene. It is anticipated that this initiative will advance innovative lightweight graphene composites and their related modelling, designing, manufacturing, and joining capabilities suitable for automotive industry which requires uni-que levels of affordability, mechanical performance, green environmental impact and energy efficiency. This leads to complete understanding of the new graphene composites and their applicability in high--volume production scenarios

24


PL 01

FROM GRAPHEnE TO CARBOn FIBRES: MECHAnICAL PROPERTIES AnD STRESS TRAnSFER In COMPOSITES

Costas Galiotis

Dept. of Chemical Engineering, University of Patras & FORTH/ ICE-HT, [email protected]

SUmmaRy: Graphene is an ideal 2D crystal which possesses a unique combination of mechanical properties in tension; that is high stiffness (~1 TPa), high strength (>100 GPa) but also high ductility (>20%). Several experiments confirm graphene as the strongest material ever measured but there are still a number of open questions as the above values have been derived from a bending experiment employing certain assumptions regarding the bending stiffness of the flake and the expected nonlinear form of the derived stress-strain curve. In compression monolayer graphene is expected to buckle at extremely low strains. This picture however changes dramatically when graphenes are embedded in polymer matrices such as PMMA. As shown recently by our group, exfoliated monolayer graphene exhibits a compression strain to first failure (Euler buckling) of 0.6% which is indeed a very high value for its overall dimensions (typically 30 by 20 μm). Furthermore, the obtained values are not affected by the flake size and can be modelled quite adequately by considering Winkler-type of mechanics upon loading.

PAN-based carbon fibres are indeed graphene 3D structures that possess excellent mechanical pro-perties in tension but their compression performance is far from optimum. Current processing para-meters such as carbonisation in combination with drawing and graphitisation temperature can affect dramatically the tensile and compression properties. Various models that have appeared in the litera-ture over the last 40-50 years to account for structure-mechanical property behaviour in carbon fibres will be presented in brief and their relation to experimental data will be discussed.

Finally, past work on the micromechanics of reinforcement of model composite systems consisting of continuous high-modulus (HM) as well as intermediate modulus carbon fibres embedded in an epoxy resin will be reviewed. It will be shown how laser Raman Spectroscopy can be employed to determine the development of stress and strain for both monoatomic graphene flakes as well as carbon fibres at microscale. By considering a simple balance of forces the derivation of the interfacial shear stress profile that governs the stress-transfer characteristics and failure processes at the interface can be derived. Si-milar results obtained from full composite systems that contain a discontinuity such as a fibre break or fibre end will be presented. Overall, commercial carbon/ epoxy systems require a maximum interfacial shear strength (ISS) of over 20 MPa for effective transfer of normal stress whereas at the nanoscale no oxidative treatment is required as the required ISS is two orders of magnitude lower due to its extre-mely small size. The lessons learnt from graphene work should assist us to produce the new generation of carbon fibres for a whole range of past and future applications.

25


PL 02

SuPERCOMPOSITES FOR AuTOMOTIVE

Nicola M. Pugno

University of Trento, Italy

[email protected]

SUmmaRy: In this plenary lecture I will present our recent activity on the analitical/numerical design and fabrication of structural bio-inspired, bionic and nanocomposites, with superior mechani-cal properties, such as strength, toughness, including advanced properties such as self-healing, all ideal for automotive applications.

26


PL-03

CRASHWORTHInESS EVALuATIOn OF COMPOSITE VEHICLE STRuCTuRAL COMPOnEnTS In AuTOMOTIVE APPLICATIOnS

Cing-Dao (Steve) Kan

George Mason University, [email protected]

SUmmaRy: Over the past decade, composite materials have been increasingly used for vehicle parts. With the recent update of the future fuel consumption standards, many structural components using composite materials have been considered and implemented into vehicle structural design. In order to fully incorporated composite materials into vehicle structural design, full vehicle crashworthiness performance needs to be considered and evaluated. Due to the material fabrication process and aniso-tropic material characteristics of composite material, accurate CAE predictive analysis for full vehicle crashworthiness performance remains to be a challenge.

In this presentation, an analysis procedure for material substitution of vehicle components, and their structural performance evaluation are first presented. In addition, a composite ladder frame vehicle chassis structure is analyzed for its performance relative to a steel frame structure. In the analysis for composite ladder frame structure, a composite material model with data implemented based on ma-terial coupon tests is considered, and structural dynamics analysis in terms of structural rigidity and structural crashworthiness performance with respect to frontal impact are performed. These analyses show progressive advancements of CAE capability in dealing with composite material characteristics and manufacturing processes. It also demonstrates deficiencies in current state-of-the-art CAE analy-sis capability.

Finally, a new design and analysis concept for composite structural intensive vehicle is introduced. In this new concept, vehicle performance metric including structural performance and crashworthiness performance is evaluated with material metric, which includes material model development and mate-rial manufacturing process, and application metric, which includes different type of loading cases, such as frontal impact, frontal off-set impact side impact and small overlap angle impact, as well as, vehicle roof crush.

27


PL 04

DEVELOPMEnT OF THERMOSET COMPOSITE STRuCTuRES FOR AuTOMOTIVE LIGHTWEIGHTInG

Frank Henning, Philipp Rosenberg

Fraunhofer Institute of Chemical Technology, [email protected], [email protected]

KEywORDS: Lightweighting, HP-RTM, Preforming, Simulation, Draping Simulation, Mold flow Simulation, Materials Methods Processes, MMD

SUmmaRy: Lightweighting has become essential for the automotive sector in recent years to meet the demands of the legislative for low emissions. One of the most promising processes to realize hi-gh-volume production of complex parts with an outstanding performance is the HP-RTM (high--pressure resin transfer molding) process chain. This contribution introduces the MMD (materials, methods and process) approach which combines the demand for structural performance and economic efficiency of composite structures. The key of this approach is the collaboration between partners to combine all expertise of virtual and real process chains for the best composite solution. The main processes for production of composites within the HP-RTM process chain are Preforming and Infiltration/Curing. For both sub-processes raw materials, simulation methods and the challenges of processing will be introduced. The preforming converts 2-dimensional fabrics into net-shaped, 3-di-mensional structures with predefined fiber orientation for easy handling and transfer to the infiltration mold. The most complex step is the forming of the 2-dimensional stack into a 3-dimensional preform. The draping simulation is essential to design a suitable draping sequence and the key for manufactu-ring of preforms without defects. The subsequent process is the HP-RTM which includes the infiltra-tion of a preform with a matrix system and the curing of the resin. The mold flow simulation predicts the infiltration behavior of the preform as well as the curing kinetics of the matrix system at different processing conditions and supports the design of RTM molds. Infiltration and curing steps can be fur-ther optimized by use of different process variants such as HP-IRTM and HP-CRTM to manufacture well impregnated composite parts with high fiber volume content. The composite properties can be adjusted by the use of different matrix systems like Epoxy resins or Polyurethanes. The MMD-approach represents a continuous development of holistic and innovative composite so-lutions, optimizing the manufacturing process chains for future requirements and demands of the market.

28


PL 05

EVOLuTIOn FP7 FunDED PROJECT - BODY STRuCTuRE DESIGn STRATEGIES uSInG nEW COMPOSITE AnD ALuMInuM MATERIALS

AnD EnABLED TECHnOLOGIES

Elena Cischino(1), Cristina Elizetxea(2), Iratxe Lopez(3), Zina Vuluga(4), Mikelis Kirpluks(5), Peteris Cabulis(6), Jesper Christiansen(7), Catalina-Gabriela Sanporean(7), John Deverill(8),

Francesca Di Paolo(9), César Maestro(10), Estibaliz Alcalde(10), Enrico Mangino(11)

(1)Pininfarina SpA, [email protected]

(2)Fundacion Tecnalia Research and Innovation, [email protected]

(3)FPK - Batz S. Coop., [email protected]

(4)ICECHIM - Institutul Naţional de Cercetare - Dezvoltare pentru Chimie si Petrochimie, [email protected]

(5)IWC - Latvijas Valsts Koksnes Kimijas Instituts, [email protected](6)RITOLS, [email protected]

(7)Aalborg Universit, [email protected] ; [email protected]

(8)AMRC with Boeing, University of Sheffield, United [email protected]

(9)IAM - Soc. Cons. Innovazione Automotive e Metalmeccanica a r.l, [email protected]

(10)Cidaut Fundación para la Investigación y Desarrollo en Transporte y Energía, [email protected] ; [email protected](11)Centro Ricerche Fiat S.C.p.A., Italy

[email protected]

KEywORDS: Body in White, Lightweighting, Composites, Aluminium, Electric Vehicles

SUmmaRy: Funded by the EC FP7 Program and based on Pininfarina Nido EV concept, EVo-lution aims to reduce the vehicle weight through new materials and process technologies, focused on five demonstrators: underbody, front crossbeam, mechanical subframe, shotgun system and door. This paper refers to body structure design strategies using new composite and Al materials and enabled technologies, focusing in particular on demonstrators design and manufacturing.

29


PL 06

THE SIMuLATIOn PROCESS CHAIn: FROM MAnuFACTuRInG TO PART PERFORMAnCE OF COMPOSITES

Andre Haufe(1), Christian Liebold(1)DYNAmore GmbH, Germany

[email protected]

SUmmaRy: The usage of reinforced composite materials in automotive industries has increased significantly within the last years due to the need to reduce weight in order to fulfill emission requi-rements as well as to increase production rates and to improve components performance. Reinfor-cements can be short, long, or continuous fibers, usually made of a carbon or glass material. A large variety of resin materials exist, but most of them can be subdivided into thermoset or thermoplastic materials. Moreover, a large variety of manufacturing processes with many varying process parameters are tested nowadays in order to reduce production costs and cycle times. For many of these production processes such as draping, thermoplastic forming, infiltration, weaving, and braiding, software tools are available which support the engineer when it comes to the question of producibility of these components. On the other hand, crash analysists are already capable to tune their simulation and material models in a way that some of the anisotropic properties of the new components can be considered within the crashworthiness analysis of the newly designed parts. This usually goes hand in hand with either reverse engineering of material parameters or cumbersome steps during the preprocessing and the model setup.But since simulation results are available from the analysis of the production process, model setup and parameter identification for crash applications can be reduced, if closing the simulation process chain during product design is feasible. For this reason a mapping algorithm called Envyo® is being developed for all different kinds of composite material processing possibilities. This does not only help to reduce the time during preprocessing and model setup of crash applications, but shall also increase the accuracy of the crashworthiness analysis since the anisotropic properties of the component can be fully considered. A proper data management based on an HDF5 data container is implemented as well, in order to fulfill the needs of reduced data storage and to follow the steps being taken along the component design. The present paper will discuss several aspects of this newly developed tool as well as showcase some examples.

31


AA AUTOMOTIVE APPLICATIONS

33


Abstract ID-35

PERFORMAnCE OF A CARBOn/CARBOn COMPOSITE CLuTCH DuRInG FORMuLA OnE RACE START COnDITIOnS

Ranvir Kalare(1), Peter Brooks(2), David Barton(2)

(1), United [email protected]

(2)The University of Leeds, United [email protected], [email protected]

KEywORDS: carbon/carbon, Formula One, multi-plate clutch, torque instability, torque inconsis-tency, surface morphology, hot banding, thermoelastic instabilities, friction radius migration

SUmmaRy: The torque output of a carbon/carbon multi-plate Formula One clutch during race starts has proved to be both unstable and inconsistent. A single clutch-plate interface dynamome-ter (SCID) was designed and commissioned to facilitate friction and thermal performance testing of single clutch-plate pairs. Replicating typical race start conditions, the SCID reproduced the pro-blematic torque instability and inconsistency. Narrow (~2mm) high-temperature (1300-1650°C) hot bands were observed during SCID tests at high rotational speeds and clamp loads typical of race starts showing that as little as only 12.5% of the full friction surface areas were in contact. The hot bands therefore indicated the location of an effective friction radius (EFR). Migration of the hot bands oc-curred between successive engagements but not during single engagements demonstrating that torque instability is due to surface morphology effects alone but that inconsistency between engagements is due to a combination of both surface morphology effects and EFR migration. Scanning electron mi-croscope (SEM) images showed that the thickness of the friction film formed on the friction surfaces appeared to become thicker as the amount of friction work increased. The SEM images also showed that in the areas where hot bands were formed, the carbon fibres appeared to be distorted although the cause of the distortion could not be determined. A thermomechanically coupled finite element analysis (TCFEA) was then developed by coupling Matlab and Abaqus to simulate the thermo-mechanical response of a single clutch-plate pair during SCID testing. With allowance for wear, the model predicts high degrees of contact localisation resulting in a single distinct hot band of comparable temperature and width to those recorded during SCID testing. The hot band and effective friction radius (EFR) were not predicted to migrate during a single clutch-plate engagement. Both the SCID and TCFEA results suggested that wear of the friction surfaces led to EFR migration between engagements but thermal expansion remained dominant during the short single engagement periods therefore preven-ting EFR migration during single engagements.

34


Abstract ID-37

InnOVATIVE AuTOMOTIVE CFRP CROSS LEAF SPRInG

Andrea Airale, Massimiliana Carello, Alessandro Ferraris

Politecnico di Torino - DIMEAS (Mechanical and Aerospace Engineering Department), [email protected], [email protected], [email protected]

KEywORDS: CrossLeafSpring, ThermoplasticComposite, CFRP

SUmmaRy: In the automotive systems the lightweight design nowadays is a mandatory target, this cause to emission normative that become strict and strict, but also for hybrid and, especially, electric vehicle to maximize the low autonomy cause to the poor energy available on batteries.Suspesion systems that are a saftey system and contribute to alla vehicle performance (dynamic, comfort, noise and vibration, etc…) is one of the most complex systems to achieve lightweight targets.In this article will be discuss the developed of a CFRP Cross Leaf Spring Prototype (TRL 6). The en-tire work flow starting from Cinematic Deisgn, Multibody Vehicle Dynamics Analys, FEM Structural Analysis, Prototype Construction, Testing and Correlations will be show. The design and engineering was taken ahead with most advanced virtual FEA techniques on composite materials that will be illus-tred. Thanks to the Prototype it has been possible to validate the realiability of the first design phases and all engineering methodologies and work flow. In this project was also studied the integration and applications of the most advanced Continous Fiber Reinforced Thermoplastic Polymer (CFRTP).This systems in comparison to traditional solutions could guarantee: more than 50% weight saving, a suspension components optimization, an optimization of the suspension volume, that means more space for people inside, easy integration of most advanced process using CFRTP and a cost sustana-bility solution.This solutions could apply to different type of Vehicle ant Truck, so the market applications is very wide and big. In this project will show the work flow developlment process and the new methodologies to can manage CFRTP design.

35


Abstract ID-43

ARE PLASTIC MATERIALS SuITABLE FOR EnGInE COMPOnEnTS?SOME POSSIBLE SOLuTIOnS

Cristiana Delprete, Carlo Rosso

Politecnico di Torino, [email protected], [email protected]

KEywORDS: Plastic Material, Engine Components, Crank Mechanism

SUmmaRy: The increasing request of power and the environmental safeguard create a series of contrasting design constraints. In order to overcome those, new materials can be employed in engine design. In the present paper, the authors evaluate the possibility to use plastic materials for designing some important parts of the crank mechanism: connecting rod and piston pin. In that particular case the material used for connecting rod is PEEK filled with carbon fiber and the material used for piston pin is carbon fiber prepreg epoxy. The usage of plastic materials allows to reduce the inertia loads and consequently the friction and vibration effects on the engine. The numerical analyses made by the authors prove that plastic materials can be useful for engine component weight reduction. Some important conclusion can be drawn: the usage of plastic materials needs a complete revision of the engine components and the changing of design strategies. The most important lesson learning is that the direct substitution of metal component with plastic one is not possible and that the increasing improvement of plastic material performance and the new technology for additive manufacturing can completely change the way of think about engine.

36


Abstract ID-51

CARS: CARBOn FIBER REInFORCED STEEL FOR STRuCTuRAL AuTOMOTIVE APPLICATIOnS

Christian Lauter, Julian Loeseke, Zheng Wang, Thomas Troester

Paderborn University, Automotive Lightweight Construction (LiA), [email protected], [email protected], [email protected],

[email protected]

KEywORDS: Fiber Metal Laminate (FML), Sandwich Structure, Hybrid Structure, Composite, Lightweight Design, Manufacturing Process

SUmmaRy: Lightweight design becomes more and more important against the background of eco-nomical and ecological constraints. Several relevant approaches for lightweight design are available in the different industrial sectors, e. g. for automotive or aircraft applications or machinery and plant en-gineering. Currently, main trends are the use of higher strength metals or the combination of materials. A promising approach in the field of multi-material systems is the manufacturing of structural parts consisting of steel metal blanks with local carbon fiber reinforced plastic (CFRP) patches.Current research at the Chair for Automotive Lightweight Design (LiA) at the Paderborn University concentrates on the investigation of hybrid materials and their processing. In particular, new produc-tion processes like the prepreg-press-technology are developed to make hybrid components attractive and available for mass production e. g. in the automotive or aircraft sector. This includes trimming process chains, reducing cycle times and thus a reduction of process steps and costs. Other fields of research are the development of new materials and material systems, the characterization of materials or the testing of components e. g. under dynamic and crash loads.The available paper focusses on an innovative large-scale production process for multi-layered sheet--metal-FRP-structures. Those fiber-metal-laminates (FML) like GLARE or ARALL are widely used for aircraft applications because of their specific advantages. Components are typically manufactured by autoclave or similar processes, which are characterised by long cycle times of sometimes several hours. Additionally, FML-components normally show a small degree of deformation. The develop-ment of the new production process started with these disadvantages. The prepreg-press-technology was used as a basis for the process. In combination with a tooling-dependent forming operation and a pre-curing of the epoxy resin in the closed mould, cycle times of under 5 minutes are achievable for structural components like hat-sections. The post-curing is realised in a subsequent oven or ca-thodic dip painting process. In this paper different process routes for the manufacturing of CFRP--steel-hybrid-structures (CarS) are illustrated. Afterwards results for the mechanical performance of specimens as well as micrographs are discussed. The paper finishes with results of crash tests of hybrid hat sections.

37


Abstract ID-54

nOVEL CERAMIC COMPOSITES FOR FIRE RETARDAnT APPLICATIOnS In AuTOMOTIVE AnD PuBLIC TRAnSPORTATIOn

Patrick Weichand, Rainer Gadow, Miguel Jimenez Martinez

IMTCCC, University Stuttgart, [email protected], [email protected], [email protected]

KEywORDS: Resin Transfer moulding, Hybrid Composites, CMC, Basalt fiber, fire retardant ap-plications, lightweight materials

SUmmaRy: Polymer Matrix Composites (PMC) are widely used in lightweight applications. The manufacturing technologies are fully developed and raw materials are cheap. Excellent mechanical pro-perties in combination with low density qualify them as an ideal lightweight material. The limiting factors of these reinforced polymers are the maximum useable service temperature well below 250 °C and poor tribological properties. Similar disadvantages can be detected for light metals. Widely used aluminum alloys show significant softening effects, already at slightly elevated temperatures at about 300 °C, and therefore restrict the possible application temperatures. On the other end of the temperature scale, Ceramic Matrix Composites (CMC) are suitable for ser-vice temperatures well above 1000 °C. These composites are composed of ceramic matrices combined with ceramic fibers based on alumina or silicon carbide. This class of composites is handicapped by the high cost of processing and raw materials, especially the expensive ceramic fibers, and therefore only attractive for applications in astronautics and military aviation. Composite materials, bridging the gap between PMC and CMC, are manufactured by the use of polysiloxanes and basalt fibers. Such competitive free formable Hybrid Composites are capable for lightweight applications in a tempera-ture range between 300 and 650 °C. Short time exposure up to over 1000 °C with decent mechanical loads is possible, also in oxidative atmosphere. In order to qualify the material for series applications, manufacturing technologies like Resin Transfer Moulding (RTM), filament winding, Pultrusion or pressing techniques are employed. Cheap raw materials in combination with capable manufacturing technologies establish completely new markets for intermediate temperature composites. These attri-butes enable the Hybrid Composite as ideal material for fire retardant applications in automotive and public transportation. Beside an increased thermal stability compared to polymeric composites, the Hybrid Composite shows excellent tribological properties. An adjustable value of hardness and coefficient of friction open up a wide variety of friction applications. The presentation will comprise a detailed view on the manu-facturing processes, a comprehensive (raw-) material characterisation and will discuss already proven industrial applications.

38


Abstract ID-58

A COMPOSITE CHASSIS FOR A FORMuLA STuDEnT VEHICLE

Luis Sousa, Virgínia Infante, Ricardo Ferreira

Instituto Superior Tecnico, [email protected], [email protected], [email protected]

KEywORDS: Tubular space frame, monocoque chassis, torsional stiffness, bonded joint

SUmmaRy: This work aims to compare different types of chassis used in a Formula Student team car. This comparison is done under the same circumstances for all structures: the suspension lines and packaging of main components are fixed and a target value for torsional stiffness is estimated based on the car’s handling balance. The space frame tubular structure from the older prototype is re-analysed and structural optimization is used to point out the torsional stiffness target value while aiming for weight reduction. A quick overview of the composite materials is presented along with the explanation of the equivalency process. A model to identify lay-ups for the different chassis zones is developed. Several arrangements were analyzed for the semi-monocoque and monocoque, aiming for the target value for torsional stiffness, considering two processes: vacuum infusion and prepregs. The final lay--ups for each case are analyzed under the critical loads. Additionally, a local study is developed in order to define the dimensions for the inserts that must be used in the monocoques’ pickup points. The prepreg constructions lead to higher weight savings. Since all the structures fulfil the torsional stiffness goal, the weight is an important factor in this comparison. It can be concluded that a Prepreg construction allows a considerable weight reduction on the car, about 12Kg.The decision between a semi-monocoque and a monocoque structure should be evaluated not only in terms of weight but also considering the advantages in terms of assembling and disassembling of the powertrain systems and components.

39


DOS DESIGN, OPTIMIZATION

AND SIMULATION

41


Abstract ID-02

DRAPE SIMuLATIOn SuPPORTED DIFFEREnTIAL DESIGn APPROACH FOR COST EFFICIEnT COMPOSITE AuTOMOTIVE STRuCTuRES

Per Mårtensson(1), Dan Zenkert(2), Malin Åkermo(2)

(1)KTH/Volvocars group, [email protected]

(2)Royal institute of technology, [email protected], [email protected]

KEywORDS: Composite design philosophies, Manufacturing constraints, weight optimization, composites, automotive, multi objective optimization, cost efficient

SUmmaRy: The importance of design for manufacturability when designing composite structures for high volume automotive applications is great. One key aspect of the producibility and the quality of the final part, as well as the level of complexity of manufacturing operations, is the formability of fibre fabrics. Simulations of this forming, in the composite industry referred to as draping simulations, can greatly improve the manufacturability of the design. Normally draping simulation are considered in later phases of development project, supporting structural design with effects on fibre angles and fibre fraction changes due to draping. However, draping simulations will also indicate where areas becomes too complex, un-drapable, to be able to be formed using one cloth of fabric. In this paper the draping simulations are considered as guidance in preliminary design phase when defining suitable split lines in a composite structure applying a differential design approach. The simulations are considered in a greater framework to provide guidelines for a well-balanced cost and weight-effective composite de-sign. It is observed that the choice of split lines becomes more methodical and less subjective compared to previous approaches, expert judgment, also the geometric complexity can be related to the material choices made. However, draping simulations today are not optimised for high volume forming proces-ses and the work of defining split lines becomes complex. In order not to become too time consuming and complicated, draping simulations are required to use single step forming processes.

42


Abstract ID-5

AnALYSIS OF STACKInG SEQuEnCE EFFECTS OF THE ROTATInG COMPOSITE SHAFTS

uSInG A FInITE ELEMEnT FORMuLATIOn

Safa Ben Arab(1), José Dias Rodrigues(1), Slim Bouaziz(2), Mohamed Haddar(2)

(1)Faculdade de Engenharia da Universidade do Porto, [email protected], [email protected]

(2)Ecole Nationale d’Ingénieurs de Sfax, [email protected], [email protected]

KEywORDS: Rotating shaft, Composite material, Finite element method, Timoshenko theory

SUmmaRy: This paper deals with the analysis of the dynamic behaviour of rotating composite shafts and effects of fiber orientations and stacking sequences.The finite element method based on Timoshenko theory is used to model therotating composite shaft. Equivalent single layer theory (ESLT) including shear deformation, rotary inertia, gyroscopic effect and stacking sequence effects is developed for the dynamic analysis of rotating composite shafts.Results obtained are compared with those available in the literature using different theories. The good agreement in results clearly show that, in spite of its simplicity, ESLT can be effectively used for com-posite rotor dynamic analysis. Results reveal that fiber orientations and stacking sequences have signi-ficant effects on the dynamic characteristics of rotating composite shafts. The analysis of different cases proves also the possibility of using composite materials in some applications of rotating hybrid shafts.

43


Abstract ID-09

COMPREHEnSIVE nuMERICAL SIMuLATIOn OF HIGH PERFORMAnCE SMC COMPRESIOn.

Laura Oter Carbonell(1), Christophe Binetruy(2), Sebastien Comas Cardona(3), Christophe Aufrere(4)

(1)Ecole Centrale Nantes, [email protected]

(2)Ecole Centrale de Nantes, [email protected]

(3)Centrale Nantes, [email protected]

(4)Faurecia, [email protected]

KEywORDS: Sheet Moulding Compound, fibres orientation, squeeze flow

SUmmaRy: Compression moulding of SMC is very popular in the automotive industry because of its high volume capabilities. In the SMC process, a charge of a composite material (which typically consists of a matrix composed of an unsaturated polyester or vinylester, reinforced with chopped glass fibres or carbon fibre bundles and fillers) is placed on the bottom half of the preheated mould. The charge usually covers 30 to 90\% of the total area. The upper half of the mould is closed rapidly at a speed of about 40 mm/s. This rapid movement causes the charge to flow inside the cavity. The reinforcing fibres are carried by the resin and experience a change of configuration during the flow. This strongly influences the mechanical proper-ties of the final part. The process simulation must track the entire fluid flow history in order to be able to predict the final reinforcement structure, and subsquently, the induced mechanical properties.Compression moulding of SMC can also generate several defects. Among them, weld lines are critical because they have poor mechanical properties normal to the weld line, as the fibres tend to align the-mselves along the weld line.In this work, a simulation tool has been developed in order to predict the spatial and time evolution of the reinforcing structure of the SMC during the compression phase. In a first part, we present the developed fluid-flow model which tracks the position of the flow front of the composite charge during the process. Once the evolution of the flow pattern is obtained, the fluid domain of the problem is defined, and the actual path followed by the fluid inside the mould is known for any planar geometry. In a second part, introduction of the orientation and transport equations of the reinforcement fibres is performed. Finally, the influence of the confinement of the reinforcement fibres due to the mould cavity thickness to fibre length ratio is introduced in the fibre orientation transport model. The segregation phenome-non is also discussed.

44


Abstract ID-21

ITERATIVE DETERMInATIOn OF THE TAILORInG OF BLAnKS FOR A WASTE-FREE COMPOSITE FORMInG BY MEAnS

OF FInITE ELEMEnT FORMInG SIMuLATIOn

Dominik Dörr(1), Lukas Lipowsky(1), Fabian Schirmaier(1), Luise Kärger(1), Frank Henning(2)

(1)Karlsruhe Institute of Technology, [email protected]

(2)Karlrsruhe Institute of Technology / Fraunhofer ICT, Germany

KEywORDS: composite forming, thermoforming, draping, Finite Element forming simulation, thermo-plastic UD-Tapes

SUmmaRy: Forming of composite pre-products into complexly shaped geometries is one of the most determining process steps in composite manufacturing. Draping of textile structures and subse-quent infiltration with a thermoset by e.g. resin transfer molding is one possible process route. Another, increasingly important role plays the manufacturing of structural vehicle components by high volume thermoforming processes of thermoplastic pre-impregnated unidirectional or woven fiber architectu-res. Dependent on the chosen tailoring of the blank, the outer contour of the formed part conforms more or less to the desired contour. If complex shapes are formed, an educated guess of an optimal tailoring of the blank, which leads to a waste-free production of the part, is usually not feasible.Finite Element forming simulation offers the possibility of a detailed analysis of the deformation of the blank during forming, considering material behavior and process conditions. The final shape of the blank, as well as stress and strain distributions can be predicted due to the modelling of the relevant deformation mechanisms. As a result, the contour of the finished product can be predicted by means of Finite-Element forming simulation with good coincidence between simulation and experimental trials, as shown by Dörr et al. in [1].In this work, an iterative method is presented, which utilizes the FE forming methods presented in [1] and enables a reliable determination of an optimal tailoring of the pre-product, leading to a pre-ferably waste-free forming process. To do so, the nodes describing the desired final shape are tracked inversely from the formed geometry to the initial position on the pre-product. The forming behavior of a suchlike trimmed pre-product may, however, considerably differ from the forming behavior of the initial geometry. To prevent this influence of the trimmed outer contour, the FE-based procedure is conducted iteratively. This iterative approach, including the applied FE forming methods, will be pre-sented. Furthermore, an application to generic geometries and a laminate of thermoplastic UD-tapes will be demonstrated.

[1] Doerr et al., „A Method for Validation of Finite Element Forming Simulation On Basis of a Poin-twise Comparison of Distance and Curvature“, Key Engineeing Materials – ESAFORM 2016.

45


Abstract ID-23

METHODICAL DESIGn PROCESS FOR STRuCTuRAL FRP SYSTEMS

Jonathan Schmidt(1), Benedikt Heuer(1), Anna-Lena Beger(1), Zhuzhell Montano(1), Hendrik Hoffmann(1), Jörg Feldhusen(1), Dave Cadwell(2)

(1)Chair and Institute for Engineering Design, [email protected], [email protected], [email protected],

[email protected], [email protected], [email protected](2)Bentley Motors Limited, United Kingdom

[email protected]

KEywORDS: Methodology, Lightweight design, FRP, Product architecture

SUmmaRy: The fully integrative composite part is the dream of every designer delivering a cost-efficient lightweight design, but due to multiple reasons this is seldom achieved. In order to completely exploit the potential of fibre-reinforced plastic (FRP) parts an adaption of the product architecture nee-ds to be made which involves several risks. Hence a “not-CAD-driven” design process has to be applied to allow quick concept changes on a high level. Using a function based method related to the approach within the standard VDI 2221, a channel and contact model developed by Mat-thiesen (cf. Matthiesen, 2002) is refined to suit a structural FRP assembly. Furthermore, ele-ments of Ashby (cf. Ashby, 2005) and Hufenbach (cf. Hufenbach et al., 2010) are applied and a morphological matrix is used to develop different product architectures and con-cepts. The key results of the paper are the detailed methodology and its implementa-tion at Bentley Motors Limited. This methodology carves out the functions to be im-plemented into a FRP part in order to exploit the full potential of composites and supports the decision between different potential resins and fibres. This leads to a new product ar-chitecture for an existing system, which considers the material specific requirements and properties. In the end, this methodology allows the designer to rethink a system without losing himself in a time consuming CAD design process.The full paper will provide detailed information about the different design steps and the combinations of the tools mentioned above. Based on the research and experience gained during an implementation at Bentley Motors Limited new CFRP concepts will be presented.

46


Abstract ID-60

TOWARDS THE CHARACTERIzATIOn OF BEHAVIOuRAL unCERTAInTY On CFRP LAMInATES

Amélia Loja(1), Alda Carvalho(2), Tiago Silva(3)

(1)ISEL, ADEM, [email protected]

(2)ISEL, ADM, [email protected]

(3)UNL, FCT, [email protected]

KEywORDS: Parametric uncertainty characterization, CFRP laminates, Finite element analysis, Structural response variability

SUmmaRy: The design of a single composite structure often imposes that particular operating and safety requirements are predicted and fulfilled. The computational prediction of structural responses should then consider not only the expected conditions and requirements, but also the uncertainty inherent to the modelling process. This uncertainty may appear, for instance, associated to the boun-dary conditions, structural loading and the set of modelling parameters, being the latter concerned to material and geometric characteristics of the structure. Despite the origin of the uncertainty, it has effect in the overall structural response. The perception of the impact of this non-deterministic reality on the modelling and behavioural simu-lation of a fibre reinforced composite enhances a more complete prediction of its expected behaviour. Moreover, this kind of predictions gives us tools that may be useful for the structural analysis and for the optimal design of composite structures.In the present work, the authors intend to characterize the relative influence of uncertain material and geometrical parameters on a set of structural responses. To this purpose, linear static and free vibration analyses of laminated composite plates will be carried out considering that the elastic properties as well as layers’ thicknesses and fibre orientation angles include uncertainty. A set of simulations and nume-rical results will be presented and discussed.

47


Abstract ID-67

STRuCTuRES WITH ACTIVE AnD PASSIVE VIBRATIOn COnTROL: PARAMETER ESTIMATIOn OF VISCO-PIEzOELECTRIC

MECHAnICAL PROPERTIES

Vitor Carvalho(1), Aurélio Araújo(1), Jorge Belinha(2)

(1)IDMEC/IST, [email protected], [email protected]

(2)INEGI/FEUP, [email protected]

KEywORDS: plate, piezo-viscoelastic, identification

SUmmaRy: Vibration control is an engineering problem within the research field of composite materials and adaptive structures. Sandwich structures with integrated capabilities of active and/or passive attenuation of mechanical vibrations have wide use in various types of industries, with special emphasis on the automotive industry. The purpose of using this kind of structure is not only an issue of structural integrity, but also of human comfort.In this work, we present a technique for identification of the frequency and temperature dependent piezo-viscoelastic properties of sandwich structures with viscoelastic soft core and elastic-piezoelectric faces. The identification process consists in the adjustment of a numerical frequency response function (FRF) to an experimental FRF. A genetic algorithm is used and the visco-piezoelectric properties are the design variables of the minimization problem. The numerical FRF is obtained using a sandwich plate finite element model with viscoelastic soft core and elastic-piezoelectric faces. The model is simi-lar to the one presented by Araujo et al. [1], considering a mixed layerwise approach.The purpose of this paper is to assess, through numerical simulations, the accuracy of the presented technique considering the real dynamic behavior of this kind of structures. The forced vibration results are obtained using a 3D FEM Ansys model, for an example of a sandwich with viscoelastic core and pie-zoelectric external faces. Finally, the accuracy of the method is verified through simulated experimental data and the identifiability of the material parameters is discussed based on the obtained results.

References[1] A. Araújo, V. Carvalho, C. Mota Soares, J. Belinha and A. Ferreira, Vibration Analysis of La-minated Soft Core Sandwich Plates with Piezoelectric Sensors and Actuators, Journal of Composite Structures, 2016.

49


GHnGREEN, HYBRID

AND NEW COMPOSITES

51


Abstract ID-04

ALuMInuM HYBRID SQuARE TuBE BEAM REInFORCED BY A THIn GLASS-FIBER COMPOSITE SKIn LAYER

Nak-Sam Choi(1), Hyung-Jin Kim(2)

(1)Hanyang University, [email protected]

(2)Samsung, [email protected]

KEywORDS: Aluminum hybrid square tube beam, glass fiber reinforced plastic skin layer, specific bending energy absorption

SUmmaRy: Bending energy absorption capability of aluminum - glass fiber reinforced plastic (GFRP) hybrid tube beams was analyzed with particular focuses on effects of thin reinforcing skin layer in relation to bending fracture characteristics. Various hybrid tube beams were fabricated by inserting adhesive film between prepreg and metal layers and by aligning various composite ply an-gles. Under 3-point bending loads, the hybrid tube beams having a 0.5mm thick [0°/90°]s skin layer showed the largest improvement in specific maximum moment and energy absorption. In short, there was an optimal thickness and layup of the composite skin layer for creating the best performance of the hybrid tubes.

52


Abstract ID-11

InnOVATIVE BIO-BASED COMPOSITES FOR AuTOMOTIVE APPLICATIOnS

Amparo Verdu, Rosa Gonzalez Leyba

AIMPLAS, [email protected], [email protected]

KEywORDS: Biocomposites, Fibres, Fabrics, Woven, Non-woven, Automotive interior, PLA, PHB

SUmmaRy: Biobased materials continue to grow in importance globally in a wide variety of indus-trial sectors, especially in automotive applications. AIMPLAS has wide experience in this field, having worked on different projects at European level. BIOFIBROCAR and ECOPLAST projects are an example of them.BIOFIBROCAR ‘Melt spun fibres based on compostable biopolymers for application in automotive interiors’ funded within the scope of the 7th European Framework Programme (G.A. nº 315479, FP7-SME-2012-SME). This project aimed the substitution of different polyester/polypropylene woven and non-woven fabrics found in a vehicle interior by novel PLA-based fibres developed using melt spinning techniques. It has been developed a compound that is able to fulfill the requirements for automotive interior applications, including such aspects as thermal resistance, fogging, odour emis-sions, VOCs and antimicrobial resistance. A final prototype of a moulded door panel were obtained by combining two non-woven layers and a woven fabric into a composite of 100% bio-based material.ECOPLAST ‘Research in new biomass-based composites from renewable resources with improved properties for vehicle parts moulding’ is a SME Collaborative Research Project funded by the Euro-pean Commission within the 7th Framework Programme (NMP) (G.A. 246176). Specific develop-ments for interior applications with improved thermal, mechanical, odour and volatiles emissions pro-perties were carried out, like the improvement of polyhydroxybutyrate (PHB) mechanical properties through the addition of natural reinforcements based on mats and fabrics of natural fibres. Long-fibre composites were produced by both compression moulding and continuous impregnation by cast sheet extrusion to study the effect on flexural properties. The reinforcing effect of flax and kenaf mats was proved, leading to a greater effect when continuous impregnation of long-fibres was performed.

53


Abstract ID-19

MECHAnICAL PROPERTIES OF SELF REInFORCED POLYAMIDE BASED COMPOSITE SYSTEMS

Paolo Vecchione(1), Domenico Acierno(2), Pietro Russo(3)

(1)Department of Chemical, Materials and Industrial Engineering - University of Naples Federico II, [email protected]

(2)CRdC Tecnologie scarl, [email protected]

(3)Institute for Polymers, Composites and Biomaterials - National Research Council, [email protected]

KEywORDS: Self reinforced polyamide, Mechanical properties, Thermoplastic composites

SUmmaRy: In the last decades polymer composite systems have ever more replaced traditional ma-terials in many industrial fields. This outstanding success, generally attributed to specific peculiarities as lightness, versatility and high specific properties, is mainly related to the achievement of a satisfac-tory adhesion at the interface between the matrix and the reinforcement as well as to the aspect ratio of this latter. However, relatively recent alternative materials, best known as single polymer composites (SPC), are gaining a growing interest both from industrial and academic standpoints because they overcome adhesion problems and show easier processability/recyclability and interesting mechanical performances compared with traditional systems reinforced with traditional glass or carbon fibers. SPCs, developed in the early ‘90s, are obtained according to a technology best known as “hot compac-tion”, essentially based on inherent structural features of semi-crystalline polymers as the co-existence of crystallites with different melting temperature and/or the ability to crystallize in two or more poly-morphic modifications. In this contribution, according to this latter approach, authors focus the attention on polyamide based systems obtained by stacking a predetermined number of woven cloths and compacting assemblies by compression molding. In more details, 24, 30 and 36 predried cloth layers from three commercial polyamide based textiles are arranged in an opportune symmetrical way and compressed at 80 bar and 220 °C for 5 min to obtain as many sheet samples with thicknesses ranging from 1.5 to 4.5 mm. Composite plates, opportunely trimmed at the edges, are cut in specimens of adequate size for the subsequent mechanical characterizations. Preliminary analyses, involving flexural static and dynamic measurements carried out according to a three-point bending configuration and Charpy impact tests, highlight interesting perspectives of the investigated self reinforced materials in many industrial appli-cations as in the automotive field in which the use of items based on all-polypropylene based systems has been already reported.

54


Abstract ID-24

MECHAnISM-BASED SPECIFIC DESIGn IMPROVES THE TEnSILE BEHAVIOR OF HYBRID MATERIAL SYSTEMS COnSISTInG

OF DIFFEREnT SHEET METALS

David Hummelberger(1), Kay André Weidenmann(2), Luise Kärger(1), Frank Henning(1)

(1)Institute of Vehicle System Technology, Karlsruhe Institute of Technology, [email protected], [email protected], [email protected]

(2)Institute of Applied Materials, Karlsruhe Institute of Technology, [email protected]

KEywORDS: hybrid material systems, automotive composites, tensile behavior, physical mechanis-ms, failure modelling

SUmmaRy: Hybrid material systems combine different types of materials and their properties. Due to the variety of design and variation options, hybrid materials are applicable to fulfill different require-ments which are imposed on structural components. Despite the fact that hybrid materials are already partially in series, a comprehensive understanding for the specific selection and association of materials of the composite is still lacking in many areas. For optimized design of future vehicle structures the profound knowledge regarding the interaction between the linking partners is of great importance. A systematic analysis and evaluation of the physical mechanisms of hybrid material systems should close this scientific gap. Therefore, based on the requirement specifications of the automotive industry, different hybrid solutions and especially their underlying mechanisms are examined and evaluated experimentally and numerically on coupon level in terms of rigidity, strength and failure behavior un-der quasi-static tensile load. The influences of different variation parameters such as layer thicknesses, number of layers as well as the used adhesive system are investigated and also analyzed by statistical methods. The developed numerical models are evaluated and discussed based on the experimental results. The results of these investigations demonstrate that specific hybrid composites constructed of sheet metals with different strength or stiffness levels improve the elongation at break as well as the tensile strength of the composite. Furthermore, the underlying mechanisms, which are caused by the interaction of the combination partners, are systematically considered and discussed. We pronounce the occurring mechanisms localization hindrance and transversal contraction hindrance. In summary, understanding the interactions between the individual components of the hybrid composite helps to design material composites with improved tensile behavior.

55


Abstract ID-40

LOWER COST, LOWER WEIGHT, AnD GREEnER POLYPROPYLEnE BIOCOMPOSITES

FOR AuTOMOTIVE APPLICATIOnS

Mihaela Mihai, Karen Stoeffler

National Research Council Canada, [email protected], [email protected]

KEywORDS: Bioblends, Biocomposites, Polypropylene, Automotive applications, Light-weighting

SUmmaRy: This paper discloses methods to produce sustainable blends and composites based on polypropylene (PP) as viable eco-solutions for automotive interior applications. Different biomaterials based on PP were prepared, containing up to 50 wt.% of renewable content (cellulosic fibers and/or polylactide). These biomaterials were evaluated in terms of morphology, mechanical, and thermal properties, as well as for cost and weight reductions. The tensile strength, tensile modulus, and heat deflection temperature presented at least equivalent values comparing to neat PP and to com-mercial PP compounds currently used in automotive interior parts. Foamed parts, obtained from these biocomposites through foam injection molding process, presented at least similar properties as unfoamed and commercial grades while being up to 25 wt.% lighter, 33 % less expensive, and 50 wt.% greener.

56


Abstract ID-41

BIOCOMPOSITES AnD BIOBLEnDS BASED On EnGInEERInG THERMOPLASTICS

FOR AuTOMOTIVE APPLICATIOnS

Mihaela Mihai, Karen Stoeffler

National Research Council Canada, [email protected], [email protected]

KEywORDS: Bioblends, Biocomposites, Automotive applications, Polyamide, Acrylonitrile-buta-diene-styrene, Light-weighting

SUmmaRy: This paper presents viable solutions concerning the formulation, processing and perfor-mance of biocomposites and bioblends based on engineering thermoplastics for application in automo-tive interiors. Polyamide (PA6) and acrylonitrile-butadiene-styrene (ABS) were formulated to produ-ce biocomposites containing up to 40 wt.% cellulosic fibers. Bioblends of PA6 and ABS containing up to 30 wt.% polylactide (PLA) were obtained as well. Finally, different biocomposites were compoun-ded based on PA6 / PLA and ABS / PLA blends containing cellulosic fibers. These biocomposites and bioblends were evaluated in terms of morphology, mechanical and thermal properties, as well as for cost and weight reductions. The tensile strength, tensile modulus, and heat deflection temperature presented at least equivalent values as neat PA6, neat ABS and commercial grades currently used in the fabrication of automotive interior parts. Furthermore, foamed samples obtained from these biocom-posites through injection foaming process presented similar properties as unfoamed and commercial grades while being up to 10 wt.% lighter, 37 % less expensive, and 40 wt.% greener.

57


Abstract ID-62

CRuSH PERFORMAnCE OF FOAM FILLED TuBES MADE OF ALuMInIuM ALLOYS AT DIFFEREnT LOADInG COnDITIOnS

Isabel Duarte(1), Matej Vesenjak(2), Lovre Krstulović-Opara(3)

(1)Department of Mechanical Engineering, TEMA, University of Aveiro, [email protected]

(2)Faculty of Mechanical Engineering, University of Maribor, [email protected]

(3)Faculty of Electrical Engineering, Mechanical Engineering and Naval Architecture, University of Split, [email protected]

KEywORDS: Aluminium alloy foam, Foam-filled structures, Compressive behaviour, Deformation mode

SUmmaRy: Road transport is one of the major sources of CO2-emissions, the main greenhouse gas. Legislation and regulations have initiated the vehicle manufacturers to reduce the environmental impact of their products and manufacturing processes. To achieve this, they have been encouraged to use lightweight environmentally friendly materials for reducing the weight of their vehicle’s body and therefore reduce the vehicle’s fuel consumption (lower CO2-emissions), as well providing enhanced safety, comfort and performance and maximizing the fuel efficiency. This can be achieved based on the multi-material concept in design by using a combination of light and cellular metals. This study pre-sents the developed and testing of lightweight structures filled with different cellular metals (e.g. open and closed-cell foams) for use as fillers in multifunctional construction elements for energy and sound absorption and vibration damping. New technologies and strategies have been also considered in order to fabricate structures which are easily molded into any shape or size as per requirements, as well as to eliminate the additional joining step which is one of the main cost drivers of multi-material-design in the automotive industry. New in-situ and ex-situ aluminum structures have been developed wherein the joining between the filler and hollow structures is achieved during the formation of the filler (e.g. aluminum alloy foam), or the previously prepared filler is directly inserted into the hollow structures, respectively. This paper presents the main results of this study in which the crush performance and de-formation modes were evaluated using uniaxial compressive and three-point bending tests supported by infrared thermography. The results have shown that these new in-situ structures have a superior mechanical performance ensuring a high ductility and a very good crashworthiness behaviour since they deform under compressive and bending loads without formation of cracks and without abrupt failure. The results have also indicated that a good interface bonding contributes to a more axisymme-tric compressive deformation. We believe that the incorporation of such structures into the automotive structures can further reduce the vehicle weight, increase the active safety in case of an accident and increase the passive safety by reducing the noise and vibrations while driving.

59


IDFFIMPACT, DAMAGE, FATIGUE

AND FAILURE

61


Abstract ID-01

IMPACT EnERGY EFFECTS On THE DAMAGE BEHAVIOR OF GLASS FABRIC/RECYCLED POLYOLEFIn COMPOSITE LAMInATES

Pietro Russo(1), Giorgio Simeoli(2), Antonio Langella(3), Ilaria Papa(3), Valentina Lopresto(3)

(1)National Research Council, [email protected]

(2)CRdC Tecnologie scarl, [email protected]

(3)University of Naples Federico II, [email protected], [email protected], [email protected]

KEywORDS: Composite laminates, Recycled polyolefins, Damage behavior, Impact energy

SUmmaRy: The use of thermoplastic composite systems to replace traditional materials in indus-trial applications is growing steadily since their recyclability, higher strength-to-weight ratios and tou-ghness with respect to thermosets based ones and their ability to be processed rapidly. In light of these peculiarities, as witnessed by the available literature, many research efforts have been spent so far to highlight potentials of many composite laminates focusing particular emphasis toward cost-effective systems. This is the case of continuous or woven glass fibre reinforced polypropylene composites, wide-ly investigated even to address the general susceptibility of polymer systems to internal damages caused by accidental and so-called low velocity impact events and often not visible to the naked eye. In this frame, authors, mainly driven by environmental reasons, considered the use of two types of recycled polyolefins from end-of-life car bumpers and bottle wastes to develop laminated structures. With the awareness of unavoidable impurities present in discarded plastic streams, to ensure an ade-quate interfacial adhesion, the sample preparation involved relatively low contents of an opportune compatibilizing agent, too. Preliminary results, confirming inferior impact parameters for recycled ma-trix based samples with respect to ones including virgin polypropylene, indicated an expected improve-ment of mechanical performances for compatibilized systems. In line with this research trend, to gain more insights about damage mechanisms induced by the use of polypropylene waste fractions, main aim of this contribution is to analyze effects caused by low velocity impact tests carried out under three impact energy levels. Detected impact parameters are interpreted by morphological and visual inspections of damaged areas.

62


Abstract ID-06

CRASHWORTHInESS DESIGn ISSuESFOR A LIGHTWEIGHT RACInG CAR

Simonetta Boria

University of Camerino, [email protected]

KEywORDS: Front impact, Vehicle, Crashworthiness, Lightweight, Composite, CFRP, FEA

SUmmaRy: A lightweight vehicle body structure is highly desirable for minimizing fuel consump-tion without compromising driving performance. Fiber reinforced composites comprise a category of materials that may offer advantages particularly in terms of weight, specific strength, specific stiffness when compared to both steel and aluminium. The use of composites as a structural material for auto-motive applications can, moreover, be increased by functional requirements such as energy absorption and deformation under impact loading. In this context, the crash safety performance of a racing car is evaluated. The crashworthiness design of a vehicle for front impact requires performance evaluation of the entire body assembly. Due to the complexity of the car design, nonlinear geometric and material behaviour of body components with contact forces under impact loading can be best analysed by explicit finite element codes, such as LS--DYNA. A CAD model of the vehicle is obviously the starting point for development of a detailed finite element model. The full vehicle front impact simulation against a rigid barrier is carried out considering different impact attenuator structures, that are the main parts of the front body subsystem which protect passengers from the collisions. In particular conventional and CFRP composite mate-rials are used during modelling. Overall vehicle deceleration responses obtained for these cases show that lighter composite impact attenuators can be more competitive than conventional absorbers of similar geometry in terms of intrusion and energy absorption in an equivalent test condition.

63


Abstract ID-10

nEW METHOD TO GEnERATE SuITABILITY ASSESSMEnTSOF COMPOSITE-METAL-HYBRID MATERIAL SYSTEMS

FOR AuTOMOTIVE CRASH STRuCTuRES

Michael Dlugosch(1), Jens Fritsch(1), Dirk Lukaszewicz(2), Stefan Hiermaier(1)

(1)Fraunhofer Ernst-Mach-Institute, EMI, [email protected], [email protected], [email protected]

(2)BMW Group, [email protected]

KEywORDS: Composite-Metal-Hybrids, Automotive Crash Structures, Hybrid Material Systems, Material Selection

SUmmaRy: EU-regulations for CO2-emissions of vehicles and growingly demanding crash-safety requirements lead to an increased exploration of novel body-in-white (BIW) materials. Using hybrid material systems consisting of advanced composites and metals in automotive structures subjected to crash loads is one solution to benefit from significant weight saving potential inherent to composites and stable, well studied crashworthiness characteristics of metals at competitive costs.A profound knowledge about the material behavior and mechanical performance requirements are necessary to successfully apply such new hybrid material systems. This work aims to computationally enhance engineering expertise in the face of a steadily expanding range of BIW-materials by proposing a numerical approach to studying the suitability of a structure to be composed of a hybrid material system using new mechanical performance criteria for a vehicle structure in a crash event. The new me-thod is used to generate comprehensive hybrid-specific sets of mechanical performance requirements by means of superimposing multiple output databases of numerical crash simulations and analyzing them with a global perspective on critical crashworthiness characteristics. The output databases of the-se finite element analyses are accessed by Python scripting to extract field and history output data. Af-ter the analysis new types of output variables are generated and implemented into the output databases in order to be visualized using regular post-processing software. A global metric for the anisotropy of the mechanical loads can be considered an important contribution to the suitability assessment of a composite-intensive hybrid material system. As part of the new method the enhancement of previous formulation includes a global anisotropy variable based on a superimposition of principal stresses and directions indicating the uniformity of an element’s global loading conditions for a set of load ca-ses. Further criteria – such as the energy absorption or plastic deformation - are evaluated to narrow down the space of suitable hybrid material systems. New insights are generated which allow for direct comparisons of the mechanical performance requirements with the crashworthiness characteristics of hybrid material systems leading to suitability assessments for materials selection. Literature references, the full scope of results and examples are included in the paper

64


Abstract ID-15

APPLICATIOn OF FIBRE REInFORCED PLASTIC SAnDWICH STRuCTuRES FOR AuTOMOTIVE CRASHWORTHInESS

Dirk Lukaszewicz(1), Lourens Blok(2), James Kratz(2), Carwyn Ward(2), Christos Kassapoglou(3)

(1)BMW Group, [email protected]

(2)University of Bristol, United [email protected], [email protected], [email protected]

(3)TU Delft, [email protected]

KEywORDS: Composite, Sandwich, Crashworthiness

SUmmaRy: In this work the application of fibre reinforced plastic (FRP) sandwich structures is being studied for automotive crashworthiness applications. Sandwiches have garnered significant at-tention with respect to in-plane impact. By contrast, the out-of-plane edgewise impact has received significantly less attention.An initial study by Lukaszewicz, Engel and Boegle has introduced a test setup for edgewise impact on a sandwich structure. The setup was then used to perform a material screening on several core systems with woven FRP skins. It was shown that Polymethacrylimid (PMI) and Polyvinylchlorid (PVC) foams exhibited the best properties with respect to specific energy absorption (SEA).A second study by Blok et al. demonstrated a manufacturing process for tufting of complete sandwich systems including the facesheets using aramid fibre. The crashworthiness of such systems was again studied for PMI and PVC foams havingskins with different layups made from non-crimp fabric (NCF). Crashworthiness was again shown to be excellent with SEA values up to 30 kJ/kg for dynamic impact. Here the lessons learned from the above studies are transferred to a full vehicle application. First, the initial sizing process is shown to introduce the early stage design process for a vehicle crash management system. Then, the crashwor-thiness of the sandwich system is simulated using the commercial Finite Element Modeling software Abaqus CZone. Lastly, full-scale impact testing on two demonstrators is performed to verify the mo-deling results. This work demonstrates the scalability of the coupon test results from previous studies from a material level into a vehicle application and the excellent modeling capability using existing FEM tools.

65


Abstract ID-17

In SITu TESTInG AnD MICROMECHAnICAL SIMuLATIOn OF FIBER REInFORCED THERMOPLASTICS

Sascha Fliegener(1), Tobias Kennerknecht(1), Matthias Kabel(2)

(1)Fraunhofer Institute for Mechanics of Materials IWM, [email protected], [email protected]

(2)Fraunhofer Institute for Industrial Mathematics ITWM, [email protected]

KEywORDS: micromechanical simulation, in situ testing, damage modeling, fiber reinforced ther-moplastics

SUmmaRy: Fiber reinforced thermoplastics are considered as promising candidates to enable the mass production of lightweight components. To assure their structural application, precise methods to describe their mechanical behavior are mandatory. In particular, the modeling of the damage behavior of the thermoplastic matrix under multiaxial stress states within the microstructure still poses enor-mous challenges. In order to capture the in situ behavior of the matrix and the fiber-matrix interface, a novel methodology is applied in our work. Micro tensile specimens, which are manufactured from 100 μm thin slices of the material’s cross section, are tested up to their failure. A corresponding finite element mesh which precisely depicts the individual microstructure of each specimen is reconstructed based on computer tomographic scans. Due to the dimensions of the specimens being sufficiently small, the position and orientation of each fiber can be mapped to the model. Micromechanical simu-lations are performed to separate the contributions of the matrix, the interface and the fibers to the global response of the specimens. It is shown that the stress-strain response of two specimens with a strongly different microstructure (fiber volume fraction of 5 and 15 %) can be accurately captured by our simulations under application of the same material parameters. Furthermore, the damage evolu-tion within the microstructure of the simulations and the experiments is visualized and compared by videos (simulation: sequence of contour plots / experiments: sequence of microscope images). The different damage behavior of both investigated specimens (normal / shear failure) is very well predic-ted by the simulations. Our combined testing and modeling procedure can thus be applied to precisely calibrate the constitutive models inversely. In future, a mapping of the experimental strain fields to the simulations would allow to take local effects into account for the model calibration. The acquired data could then be fed into larger (representative) micromechanical models to obtain the homogenized properties of the composite and finally be applied to describe the mechanical behavior of components within the framework of integrative simulation over the whole process chain.

66


Abstract ID-27

EnERGY ABSORPTIOn PROPERTIES OF BRAIDED COMPOSITE RODS

Shuhei Yasuda(1), Yuki Takagaki(2), Nobuyoshi Kajioka(2), Hiroaki Yamada(2), Yuqiu Yang(3), Tadashi Uozumi(4), Hiroyuki Hamada(1)

(1)Kyoto Institute of Technology, [email protected], [email protected]

(2)Daikyonishikawa Corporation, [email protected], [email protected], [email protected]

(3)Donghua University, [email protected]

(4)Gifu University, [email protected]

KEywORDS: energy absorption, textile composites, braided composites, impact energy absorption member

SUmmaRy: With the exhaust gas regulation of the car being strictly, the light weighting of the body is strongly demanded. In the late years, fiber reinforcement composite material which is lightweight and superior rigidity have been substitute for metal materials such as iron or aluminum which have been used conventionally. Aluminum and steel have also been used for impact energy absorption mem-ber such as side beam or bumper by the reasons of the cost, forming quality and corrosion resistance. Fiber reinforced plastics are well known as high energy absorption material by making tapered shape at one end. Tapered shape makes progressive crushing, which is fracture propagation under high load, instead of brittle fracture. Therefore, fiber reinforced plastics are prospective material for those impact energy absorption member.Textiles, such as braiding, knitting or woven fabrics, are often used as reinforcements of FRP. These textile preforms can be fabricated directly to their final shapes, so productivity could be improved by using textiles.In previous study, it had been revealed that energy absorption properties of FRP rods could be impro-ved by prevent central crack which propagate in longitudinal direction. Therefore, braided rods which have core fiber, which is unidirectional fiber that is inserted in tubular braid, could prevent central cracks by the structure of braid, and it could lead to have good energy absorption properties. In this study, unidirectional pultrusion rods were made, after that, UD rods were covered by braid. By passing this process, braided composite rods will make easier. Glass, basalt, carbon fibers were used for UD and braided fiber. All combinations of those fibers were made, and the specimens were crushed in a low speed compression test carried out at a constant value of 5 mm/min. Energy absorption amount was evaluated by Es value. Es value could express by the following equation. Es = P/Ar rP is the meaning load, A is the cross-sectional area and r is the density of the specimens. The material which have the most high energy absorption value was detected.

67


Abstract ID-48

RESIDuAL ELASTIC PROPERTIES AnD DAMAGE ASSESSMEnT In VEHICLE COMPOnEnTS MADE OF COMPOSITE MATERIALS

Alessio D’Andrea(1), Davide Paolino(1), Giovanni Belingardi(1), Brunetto Martorana(2), Vito Lambertini(2)

(1)Politecnico di Torino - DIMEAS, [email protected], [email protected], [email protected]

(2)FCA - Centro Ricerche Fiat - Group Materials Labs, [email protected], [email protected]

KEywORDS: Composite materials, NDT, Damage Index, Impact, Residual elastic properties

SUmmaRy: Damage complexity represents one of the main limitations to the diffusion of composite materials in many industrial applications. The objective of this study is to make preliminary steps to-wards an innovative simplified assessment of the damage sustained by composite materials.A methodology for the evaluation of the residual elastic properties is proposed and applied at first to damaged laminates and then to a part prototype.The composite laminate investigated in this study is made of eight twill-wave carbon fabrics impreg-nated with epoxy resin. Composite plates have been subjected to impact tests at different energy levels and residual elastic properties are subsequently assessed through tensile tests. The relationship betwe-en the impact energy and the residual elastic properties is used for the individuation of the maximum energy level that induces a negligible damage in the composite laminate (the threshold energy).The value of the Damage Index (DI) [1] obtained from non-destructive impacts at energy threshold is adopted for the prediction of the local residual elastic properties in the damaged area. The proposed methodology is applied and validated on plate specimens. A strict correlation is found between the predicted and the actual residual elastic properties of the damaged composite plate.As a second step, the methodology is applied to a composite channel section beam, that is a prototype, representative of a vehicle body beam.Also in this case some different impact tests have been done with different level of impact energy and drop mass. The consequent damage has been visually inspected and then, by application of the outli-ned evaluation procedure, the amount of the damage induced into the part has been assessed.

68


Abstract ID-49

DAMAGE MODELInG In COMPOSITE MATERIAL, An AuTOMOTIVE APPLICATIOn.

Jean-Pierre Delsemme(1), Michael Bruyneel(2), Cédric Lequesne(1)

(1)Samtech, [email protected], [email protected]

(2)GDTECH, [email protected]

KEywORDS: finite-element, simulation, composite, damage

SUmmaRy: To simulate composite material behavior, finite element method can be used. Combined with CLT, traditional element formulation can be used to perform linear elastic analysis. To predict effective behavior up to the maximum carrying capacity it is important to be able to take into material degradation. To achieve that goal it is important to use material models able to represent the different modes of degradation of the plies. Damage at the interface between the plies, that is delamination, must also be taken into account in the model.The numerical experiences are conducted with the SAMCEF finite element code. Simulation is com-pared to experimental results, and validations are done at the coupon level and at upper stages of the pyramid of tests.The material model for the intra-laminar damage is based on the continuum damage mechanics appro-ach initially developed by the Ladevèze et al. in Cachan. Damage variables impacting the stiffness of each ply are associated to the different failure modes, representing the fiber breaking, matrix cracking and decohesion between fibers and matrix. The specific damage model is first presented. Then, the basics of the parameter identification procedure of such a material model are briefly explained. This procedure is based on test results at the coupon level, and allows determining not only the elastic pro-perties but also the value of the parameters describing the non-linear behavior of the material. The cohesive elements approach is used for modeling the inter-laminar damage. The approach is also based on the continuum damage mechanics in a formulation initially developed by the Ladevèze et al. in Cachan. A damage model is assigned to interface elements inserted between plies to represent possi-ble separation. The inter-laminar damage model is presented together with the basics of the parameter identification procedure relying on DCB and ENF tests. The linear and non-linear material properties identified at the coupon level are then used to simulate intermediate complexity tests, e.g. a L-shaped beam. Comparison between tests and simulation de-monstrated the predictability of the modeling and analysis approach.

69


Abstract ID-71

DESIGn OF A COMPOSITE CRASH BOX FOR A FORMuLA STuDEnT TEAM CAR: PRELIMInARY SIMuLATIOnS AnD TESTInG

André Santos(1), Aurelio Araujo(2), José Aguilar Madeira(2), Hernâni Lopes(3)

(1)Instituto Superior Técnico, Universidade de Lisboa, [email protected]

(2)IDMEC - Instituto Superior Tecnico, Universidade de Lisboa, [email protected], [email protected]

(3)Instituto Superior de Engenharia, Instituto Politecnico do Porto, [email protected]

KEywORDS: Crash box, Impact simulation, Experimental tests, High speed imaging

SUmmaRy: In this work preliminary studies towards the development of an integrated carbon fiber crash box for a Formula Student team car are presented. The objective of the studies and tests are the assessment of the commercial explicit finite element code LS-DYNA for the impact simulation of the crash box. This software will be the basis for the design process of the composite crash box, using multiobjective optimization codes such as the Direct MultiSearch algoritm.The initial finite element simulations were conducted on aluminum cylindrical tubes subjected to im-pact loads, according to the Formula Student regulations. Experimental tests were then conducted on these aluminum tubes for an assessment of the finite element simulations. A high speed camera was used to capture the deformation patterns, as well as accelerometers mounted on the impact head, in order to determine the acceleration histories and hence the absorbed impact energy. Carbon fiber reinforced composite cylindrical tubes were also fabricated and tested in the same conditions as the aluminum specimens and new finite element simulations are being conducted in order to calibrate the model parameters required to obtain an impact response as close to the experimental results as possi-ble. The obtained preliminary results will be presented and discussed.

71


MFMANUFACTURING

73


Abstract ID-03

A nEWLY InJECTIOn MOLDInG SYSTEM FOR SHORT FIBER COMPOSITES

Akio Kataoka(1), Hirofumi Ichikawa(2), Akihiko Imajo(3), Hiroyuki Inoya(3), Hiroyuki Hamada(3)

(1)nihonyuki co.,ltd., [email protected]

(2)nihonyuki co.,ltd, [email protected]

(3)Kyoto Institute of Technology, [email protected], [email protected], [email protected]

KEywORDS: DFFIM, Injectionmolding, fiber

SUmmaRy: DFFIM is recent developed injection molding system for short fiber reinforced compo-sites. In this system vent type injection machine with controllable unit is used and continues fiber can be inserted from vent hole. The continues fiber is cut to short fiber in the screw, and finally short fiber composites can be created. There are several merits of DFDIM.fiber contents controlleddifferent fibers inserted surface treatment to continues fiber achievedTherefore our own composites can be fabricated. Among various reinforcing fibers.Carbon fiber is very high potential to create higher modulus and strength car components. However, cost problem always arisen. Even if small amount carbon fiber is contained the mechanical properties increased drastically and cost problem was also solved. In this paper several data of short fiber compo-sites fabricated by DFFIM was presented GF/CF/PP composites GF/PP+CF+PA+MAPP composites GF/CF/PC composites Throughout these data availability of DFFIM was recognized.

74


Abstract ID-12

ESTABLISHMEnT OF CVT BELT MOLDInG TECHnIQuE MADE OF CARBOn FIBER REInFORCED THERMOPLASTICS

RESIn COMPOSITE MATERIALS

Taichi Sugiura, Tatsuya Tanaka, Tsutao Katayama

Doshisha University, [email protected], [email protected], [email protected]

KEywORDS: Long Carbon fiber, Boron nitride, Slip rate, CVT blocks

SUmmaRy: In recent years, to reduce the burden on the environment in manufacturing has become important. A relatively lightweight resin has attracted attention as a substitute material for the metal material for the fuel efficiency in the automotive industry. The sliding parts of the car, blocks of the CVT belt is currently made of metal general. In the present study, we make lightweight, environmen-tally friendly CVT blocks. We are using a composite material of thermoplastic resin as a material. That is because the molding time requires relatively short.

CVT block is used for a long time at a high temperature. Therefore we use nylon 9T (PA9T) as base material, which has relatively high melting point among thermoplastics, and high strength at high temperature. To practicable CVT levels, high strength, high elastic modulus and high slidability are necessary. So they are improved by carbon fibers (CF) and boron nitride (BN). CF and BN are knea-ded with material. CF is using short fibers and long fibers.

Injection molded into CVT block type, was manufactured CVT belt. We use 3 type material. Material.A, which is added SCF40vol%, Material.B, which is added LCF25vol% and Material.C, whi-ch is added SCF40vol%BN7vol%. Belt evaluation was carried out in the power transmission capacity test and slip test. Power transmission capacity test results, the belt temperature could be kept lower in LCF than SCF.

Slip rate could be kept lower in there BN than without BN. The slip test, forcibly cause a slip during the belt operation, was observed whether return to the steady state. Result, does not return to a steady state in any material, and had melted at block surface by sliding heat generation.

From the above, production was CVT belt is enough as the power transmission capacity, but it cannot be said yet available in view of the safety.

75


Abstract ID-14

TEMPERATuRE DISTRIBuTIOn In THICKnESS DIRECTIOn OF THERMOPLASTIC LAMInATES DuRInG THERMOFORMInG

Daniel Kugele(1), Julius Rausch(2), Philipp Müller(1), Luise Kärger(1), Frank Henning(1)

(1)Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology, Chair of Lightweight Technology, Germany

[email protected], [email protected], [email protected], [email protected](2)AUDI AG, Technology Development Fiber-Reinforced Polymers, Germany

[email protected]

KEywORDS: Thermoplastic composites, Thermoforming, Temperature distribution, Finite Ele-ment Method

SUmmaRy: The combination of thermoforming processes of continuous-fiber reinforced thermo-plastics and injection molding (overmolding process) offers a high potential for a cost-effective use in automobile mass production. The advantageous short cycle time, the additional possibility of desig-ning lightweight, complex and functionalized components are one of the major benefits of such hybrid material systems. The temperature control of the laminate along the entire process chain (including transfer, thermoforming and overmolding) is crucial for the production process and has a significant influence on important component properties, such as the bonding strength between the laminate and the injection molding compound, for instance. Consequently, this paper deals with the thermal behavior of the laminate during the different proces-sing steps with special emphasis on the thermoforming process. Initially, the experimental setup for the investigation of the heat transfer between laminate and tool is presented. In this context the measu-rement method is defined, including six temperature sensors to quantify the temperature distribution in thickness direction of the laminate. Additional emphasize is placed on the influence of the laminate thickness and the fiber material (glass/carbon) which are varied during experimentation. Subsequen-tly, a simulation model based on the Finite Element Method (FEM) is presented to predict the thermal behavior during thermoforming. As a result, the influence of laminate thickness and fiber material on the cooling behavior is discussed in detail. Additionally, the simulation is validated by experiments and it can be shown that the predic-ted temperature distribution is an accurate representation of the experiments. The study contributes to a deeper understanding of a large number of thermoplastic processes and can be used to optimize process control and, consequently, component properties.

76


Abstract ID-16

MAnuFACTuRInG OF COMPLEX PARTS BASED On unIDIRECTIOnAL TAPES

Raquel Ledo, Vanessa Ventosinos

CTAG, [email protected], [email protected]

KEywORDS: Composite manufacturing, Unidirectional tapes, Carbon fibre, Glass fibre, Over moulding, In-situ consolidation, Mathematical modelling

SUmmaRy: Carbon and glass fibre unidirectional continuous tape reinforced composites are one of the most promising options to achieve the high performance composite materials demanded by the transport sector. However, the current technologies are not mature enough for a full industrial imple-mentation; main barriers are related to the high consumption of resources, lower rates of automation and high production of defective.FORTAPE* project aims to solve these drawbacks through the development of an efficient and opti-mized integrated system for the manufacturing of complex parts based on unidirectional fibre tapes. It is expected to provide wide-ranging benefits to transport sector, in particular for the automotive and aeronautical industries.The addressed challenges are:Challenge 1: Development of an efficient process for carbon fiber and glass fiber unidirectional tapes manufacturing with reduced material usage and defective production and increased mechanical per-formance.Challenge 2: Development of an innovative over-moulding technology to manufacture complex com-posite parts locally reinforced with single and bi-layer UD tapes.Challenge 3: Novel in-situ consolidation technology to manufacture complex parts without the need of autoclave for secondary structure and interior cabin applications complying with fireproof regulations.Challenge 4: Novel-modelling concepts to assess the geometry design of complex parts and to select the best strategy for the part manufacturing.The impact objectives to accomplish the main project purpose and linked to the technical objectives described above are the following ones:1. Resource efficiency during composite complex parts manufacturing. Expected values to be reached in each market target are: 40% reduction of material usage for automotive sector and 75% for aeronau-tics; 35% energy saving for automotive sector and 45% for aeronautics.2. Elimination of at least 85% in faulty manufactured parts during composite complex parts manufac-turing for automotive applications. Furthermore, within the aeronautics sector it is expected to keep performances in this sense (current average value of 7% of faulty manufactured parts production rate).* This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636860

77


Abstract ID-18

EXPERIMEnTAL AnALYSIS OF THE InFLuEnCE OF FOAM DEnSITY AnD SuRFACE TREATMEnT

On THE FAILuRE BEHAVIOR OF POLYuRETHAnE FOAM DuRInG THE RTM PROCESS

Jens Gerstenkorn(1), Guenter Deinzer(2), Martin H. Kothmann(2), Felix Diebold(2), Luise Kaerger(1), Frank Henning(1)

(1)Karlsruhe Institute of Technology, [email protected], [email protected], [email protected]

(2)Audi AG, [email protected], [email protected], [email protected]

KEywORDS: RTM process, sandwich structure, polyurethane foam, failure behavior

SUmmaRy: Sustainable lightweight design is a key technology to meet upcoming CO2 emission standards in the automotive industry. Besides metal, the use of carbon fiber reinforced plastics (CFRP) in car body increases due to its outstanding specific mechanical properties. Against this background, the Audi ultra-RTM process (resin transfer molding process) has proven its high potential for large--scale production of such components. To further improve the lightweight design quality, integration of high performance sandwich structures into integral body parts has become target of current develo-pments. The challenge is to introduce an economic and robust production process for CFRP sandwich structures using light and cost-effective cores. In this context, the excellent cost-per-kg ratio of the un-processed raw materials and the possibility of three-dimensional final shape manufacturing predestine polyurethane (PUR) foam as a core material for use in automotive mass production.For preselection and improvement of potential core materials as well as for process optimization and process simulation, it is necessary to analyze the process behavior of the material. In the context of RTM, the failure behavior of PUR foams requires a separated investigation from the deformation behavior, as shown by Gerstenkorn et al. in a previous study [1]. Hence, focus of this study is the density dependent failure behavior of PUR foams under process related conditions. A test method is introduced that allows investigation of failure behavior regarding onset of resin intrusion into the foam and continuing intrusion resistance. Therefore, a hydrostatic fluid pressure is applied on the specimens while fluid volume and cavity pressure are recorded. For detection of failure, the pressure course of sealed reference specimen is compared to unsealed test specimen. Furthermore, the influence of di-fferent foam surface treatments on the failure behavior is identified. To improve the understanding of the failure behavior, scanning electron microscope (SEM) analysis of foam specimens is carried out.[1] J. Gerstenkorn et al. Characterization of the multi-axial material behavior of polymer foams during the RTM process. Proceedings of the 17th European Conference on Composite Materials ECCM17, Munich, Germany, June 26-30 2016.

78


Abstract ID-22

A STRATEGY TO PRODuCE METAL-POLYMER HYBRID COMPOnEnTS BY ADDITIVE MAnuFACTuRInG PROCESSES

Miguel R. Silva(1), David S. Oliveira(1), Artur Mateus(1), Cândida Malça(2)

(1)IPL - Instituto Politécnico de Leiria, [email protected], [email protected], [email protected]

(2)isec - Instituto Superior de Engenharia de Coimbra, [email protected]

KEywORDS: Additive manufacturing process, Metal-polymer hybrid componentes, Selective Laser Melting (SLM), Stereolithography (SL), High performance components

SUmmaRy: The demand for components with functional characteristics and exceptional mechani-cal properties grows every days in every engineering fields from bioengineering to aeronautics. Doub-tless that there is an increasing need to develop metal-polymer hybrid components with high perfor-mance. The combination of these two materials in a single component allows to obtain components with functional gradients, which is a characteristic with high demand for high-tech applications. In the automotive industry some structural components of the chassis are an example of metal-polymer hy-brid components application. These components present low weight, high strength, corrosion resistan-ce, good impact resistance, as well as allow absorb vibrations and noise. These characteristics, among others, allow an increase in efficiency, performance and reduced vehicles consumption. Currently, metal-polymer hybrid components are produced by overmolding or compression. These conventional manufacturing processes present, however, some drawbacks mainly concerns to the com-plexity of possible geometric shapes produced. The current additive manufacturing processes are able to produce polymeric and metallic components with an unmeasured geometrical freedom. Additionally a reduced time to obtain final products is re-quired. Nevertheless the processing mechanisms of each material, metal and polymer, are very different reason for that is not known a single equipment that direct manufacturing metal-polymer hybrid com-ponents. This work presents a strategy - a hybrid additive manufacturing system – based on Selective Laser Melting (SLM) or other conventional technologies for metals, and the Stereolithography (SL) for polymers, to produce metal-polymer hybrid components.

79


Abstract ID-28

EFFECT OF FIBER LEnGTH DISTRIBuTIOn On MECHAnICAL PROPERTIES OF COMPOSITES

In InJECTIOn MOLDInG PLASTICIzATIOn

Issei Harima(1), Hiroaki Yamada(1), Nobuyoshi Kajioka(1), Yuqiu Yang(2), Hiroyuki Hamada(3)

(1)DaikyoNishikawa Corporation, [email protected], [email protected], [email protected]

(2)Donghua University, [email protected]

(3)Kyoto Institute of Technology, [email protected]

KEywORDS: Fiber reinforcement composite, Remained fiber length, Mixing ratio, Mechanical pro-perties

SUmmaRy: In recent years, the automotive industry is facing an urgent need to reduce vehicle wei-ght to improve fuel efficiency and to reduce CO2 emissions to address global warming. Especially, in Europe, the structure material development to replace steel with resin has been accelerated. The resin materials used for structure require such properties as high rigidity, high strength, and impact resis-tance. To satisfy those requirements, fiber-reinforced composite materials containing glass or carbon fiber have been widely used. In recent years, the automotive industry is facing an urgent need to reduce vehicle weight to improve fuel efficiency and to reduce CO2 emissions to address global warming. Es-pecially, in Europe, the structure material development to replace steel with resin has been accelerated.In this research, remained fiber length and mechanical property of glass fiber reinforced PP com-posited (GFPP) and carbon fiber reinforced PP composite (CFPP) were studied. Single fiber pellet composite, SFP/LFP hybrid composite and GF/CF hybrid composite were produced from short fiber pellet (SFP) L3 and long fiber pellet (LFP) L7, L11, L15 by low-shear screw injection molding machi-ne. The original reinforced fiber length of L3, L7, L11 and L15 were 1.5mm, 7mm, 11mm and 15mm respectively. Three-point bending, tensile and impact tests were conducted and after that remained fiber length was measured. It was found that GFPP and CFPP showed different trend in mechanical property at different remained fiber length. The most optimal mixing ratio of GF/CF hybrid compo-site was studied to get the best mechanical property.

80


Abstract ID-29

STuDY On ADAPTATIOn OF RECYCLED CFRTP TO THE HYBRID InJECTIOn MOLDInG

Junya Shiode(1), Tatsuya Tanaka(1), Masaya Kawashima(1), Masao Tomioka(2), Takeshi Ishikawa(2), Tatsuo Katayama(1)

(1)Doshisha University, [email protected], [email protected], [email protected],

[email protected](2)MITSUBISHI RAYON CO., LTD. Toyohashi Research Laboratories, Japan

[email protected], [email protected]

KEywORDS: CFRTP, prepreg, recycling, hybrid, injection molding

SUmmaRy: To reduce the environmental loading by the lightweight of the automotive, fiber rein-forced plastics have been expected as an alternative of metal materials. Among them, applications of carbon fiber reinforced thermoplastics (CFRTP) have been studied because of both their high me-chanical properties and mass productivity. As method of CFRTP molding, hybrid injection molding technology has attracted attention. In the hybrid injection molding, pre-heated thermoplastic inserted material is placed in the mold and preformed by clamping the mold then ribs or others are molded by injection over the inserted material. This technology makes it possible to mold complicated parts with excellent mechanical properties at high cycle. By the way, we had proposed a recycling technique of wastes of CFRTP uni-directinal (UD) prepreg sheet as pellet material for the injection molding in our previous studies. Applying our recycled material in hybrid injection molding is expected that our recycled material has good adhesion to inserted material made from its pristine prepreg, because those materials are the same by following the original. We compared the suitability as overmolding material of our recycled CFRTP and conventional short-carbon-fiber-reinforced-pellet (SFP) to confirm effect of expected adhesion between materials of the same origin. Hat-channel shaped moldings which had ribs were prepared by overmolding to continuous CFRP substrates using the hybrid injection molding machine. Molding with recycled CFRTP showed better flexural properties than molding with conven-tional SFP. Morphological observation and numerical analysis suggested that advantage of mechanical properties of molding with recycled CFRTP was caused by its better interfacial adhesion. Elevation of temperature and holding pressure of the injection resin, which might improve the interfacial adhesion between the inserted material and the overmolded material caused improvement in flexural properties of the molding. This result corresponds to above consideration that the superior mechanical properties of the molding with our recycled material result from excellent adhesion between injected one and inserted its pristine material. In any overmolding conditions, moldings with recycled CFRTP sho-wed better flexural properties than moldeings with conventional SFP. These results suggested that our recycled CFRTP present excellent interfacial adhesion in the hybrid injection molding.

81


Abstract ID-31

APPLICATIOn OF An InTEGRATED InJECTIOn APPROACH TO MAnuFACTuRInG MuLTIMATERIAL PRE-PREGS COMPOnEnTS

David S. Oliveira(1), Artur Mateus(1), Miguel R. Silva(1), Cândida Malça(2)

(1)IPL - Instituto Politécnico de Leiria, [email protected], [email protected], [email protected]

(2)ISEC - Instituto Superior de Engenharia de Coimbra, [email protected]

KEywORDS: Water assisted injection, Hollow components, Pre-pegs, Multimaterial

SUmmaRy: The automotive industry presents currently a great need for pre-preg polymeric matrix components, in particular those castings and of tubular types. The hollow section components have, in addition to low weight, a high flexural strength and may incorporate ducts with highly complex shape and submitted to elevated levels of internal pressure since reinforced with materials that promote ade-quate mechanical behavior. The manufacture of hollow section pieces is associated with the injection process assisted by a fluid - water, gas or both - with the aid of a projectile. This technology, despite the high demand, it is costly and little explored which justifies the lack of companies specializing in this production process.This work describes, through a case study of an automobile clutch pedal, the development of a metho-dology for the manufacturing of injected multimaterial parts with pre-peg fabrics and hollow section with the aid of the water assisted injection molding process. The possibility of performing the injection, with different thermoplastics, on a technical pre-preg fabrics (carbon, glass, kevlar or metal) allows ob-taining multimaterial components with high performance and hollow section, constant or not, which is very useful and advantageous for many industries but fundamentally for the automotive sector.

82


Abstract ID-33

InVESTIGATIOn OF MECHAnICAL PROPERTIES OF A FIBER FAIR JOInInG COnCEPT

FOR FIBER REInFORCED THERMOPLASTICS

Christian Brecher(1), Clemens Buschhoff(1), Henning Janssen(1)

(1)Fraunhofer Institute for Production Technology IPT, [email protected], [email protected], [email protected]

KEywORDS: Joining, Fiber reinforced thermoplastics, Insert, Demountable, Thermal drilling

SUmmaRy: To achieve lightweight parts with high mechanical requirements fiber reinforced poly-mers (FRP) are an attractive option. In particular fiber reinforced thermoplastics enable the step from high-end to economic and large scale applications such as automotive parts. The thermoplastics can be processed within seconds and have no limited shelf life. For the final applications demountable connec-tion and joining points, such as bolts, are frequently used. However, the drilling of FRP is accompanied with high material wear and a weakening of the FRP by cutting the fibers. Within this paper a demountable joining concept optimized for FRP is investigated. An insert is pu-shed within a thermal drilling process through an organo sheet (fiber reinforced thermoplastic blank). Thereby the fibers are not damaged and are aligned around the insert. The thermal drilling process heats up the organo sheet locally and melts the thermoplastic matrix around the insert. Subsequently a spike which is mounted on the insert is pushed through the organo sheet and the fibers can move in the molten matrix around the insert.The test bench shows the feasibility by successfully integrating the inserts into the organo sheet. Me-chanical tests demonstrate the improvements compared to conventional drilled holes. Furthermore an application within a generic automotive demonstrator parts is presented within this paper.

83


Abstract ID-34

SEMI-SOLID JOInInG OF ALuMInIuM AnD CARBOn FABRIC

Lukas Marx, Mathias Liewald

Institut für Umformtechnik, [email protected], [email protected]

KEywORDS: semi-solid forming, lightweight applications, aluminium, carbon fabric

SUmmaRy: Today lightweight applications within automotive and aerospace constructions are ac-companied by the development of appropriate joining concepts. Especially the combination of dissi-milar materials like aluminium and carbon poses precise requirements on suitable joining techniques: a solid connection between metal and carbon structures is inevitable, both of the materials must be intact, and the hybrid structure must be durable. With regard to these prerequisites, an innovative joining technique was developed at the Institute for Metal Forming Technology/Stuttgart (IFU). At the beginning of the novel process, a layer structure of two aluminium sheets and a carbon fabric in--between was heated up using conduction. Once the aluminium alloy has reached the semi-solid state, the woven carbon fabric is infiltrated with aluminium. In this way, a firmly bonded connection between aluminium sheets and carbon structure is put into effect. By using the thermomechanical simulator Gleeble 3800c and electrodes with circular heading surfaces (Ø 25 mm), basic investigations were con-ducted focusing on the feasibility of this new joining method. Thereby, suitable process parameters and a reliable sample heating control were developed for one single carbon layer. Experiments published in this paper show the influence of advanced electrodes with various heading surface geometries on the joining method and the tightness of the hybrid joint. Another issue of the research work described in this paper is the application of carbon multilayers with maintenance of the high infiltration level. Finally, this paper makes a contribution to the development of innovative hybrid structures in multi--material designs for automotive and aerospace constructions.

84


Abstract ID-53

IMPACT BEHAVIOuR OF PPA-GLASS FIBRE COMPOSITES AuTOMOTIVE COMPOnEnTS

Laura Gendre, Ian Butterworth, Tony Ridler

University of Warwick, United [email protected], [email protected], [email protected]

KEywORDS: Impact behaviour, PPA-Glass Fibre, Rear Drive Unit

SUmmaRy: Nowadays, car manufacturers aim to reduce the weight of the cars in order to decrease the fuel consumption as well as the CO2 emissions. They face the challenge of designing and produ-cing new lightweight components without compromising their properties and use. Through the UL-TRAN project (part-funded by Innovate UK), a novel rear drive unit was developed allowing a 25% reduction in mass compared to the current product on the market. The topologically optimised design consists of a lightweight differential mounted within a single-piece skeletal cast aluminium casing with polymer composite covers. The present study concerns the validation of the material (PPA/Glass Fi-bre) used for the covers of this component. Situated underneath the car, the unit, and in particular its covers can be subjected to stone impact projected from the road. Impact behaviour of the component was investigated with low velocity impact using a gas gun and the impact properties of the materials were characterised by plaque testing.

85


Abstract ID-65

RAPID, LOW EnERGY PROCESSInG OF POLYMERS AnD COMPOSITES

Terry McGrail, Walter Stanley, Ananda Roy, Dipa Roy

Irish Composites Centre (IComp), Mechanical, Aeronautical and Biomedical Engineering Department, University of Limerick, Ireland

[email protected], [email protected], [email protected], [email protected]

KEywORDS: Electromagnetic irradiation (EMI), Rapid processing, Polymers, Composites

SUmmaRy: Electromagnetic irradiation (EMI), such as RF and MW, can be used for rapid and low energy heating of polymers and composites but most polymers are transparent to EMI and this has historically been a barrier to this processing technology being used industrially. This problem has now been overcome by developing and incorporating suitable EMI susceptors into a polymer or composite to achieve uniform volumetric heating in the bulk of the material. In conventional processing, the heat transfer takes place through the surface whilst with EMI the heat is generated within the material itself, so the heating is uniform and devoid of any thermal gradient. This improved technology pro-vides new opportunities for rapid throughput manufacturing as well as economic and environmental advantages through energy savings. EMI heating may be used either alone or in combination with conventional heating to offer flexible processing with significant benefits. The EMI susceptors may be incorporated into any polymeric material, be it a thermoplastic, a thermoset or a blend, or into suitable composites, including self-reinforcing composites, by industrially viable routes. The choice of susceptor varies according to the base polymeric material and any filler-type materials or other additives incor-porated into it. The EMI heating process can be used for the shaping, forming or curing of polymers and composites, the selective heating of a multi-component polymeric material or for the joining of composites to composites. This processing technology has the potential for reducing the production time and manufacturing cost of composite parts for many industrial applications including the auto-motive industry.

87


nCNANOCOMPOSITES


89

Abstract ID-13

POLYPROPYLEnE nAnOCOMPOSITES WITH IMPROVED PROPERTIES FOR AuTOMOTIVE APPLICATIOnS

Luis De Prada(1), Manuel Herrero(2), Jose Maria Pastor Barajas(2)

(1)Fundacion CIDAUT, [email protected]

(2)Valladolid University, [email protected], [email protected]

KEywORDS: Improved properties, in situ polimerisation, Polypropylene, nanocomposites

SUmmaRy: Polypropylene is present in several industrial sectors, such as automotive, packaging, electrical and electronic, building and construction, etc. The mechanical and thermal properties, the easy-processing and the low cost promote it to be the highest demanded thermoplastic in Europe. To improve the properties, and ensure the competition with other materials in automotive sector, poly-propylene is reinforced for many applications. In this sense, it is very common to use composites with talc or glass fiber in structural parts. The newest road, and not yet extended in this sector, is the use of nanometric scale reinforcements, which can provide and/or improve the polymeric matrix properties with low amounts of nanoparticle (<5%).Polypropylene/clay nanocomposites are usually obtained by melt intercalation, where at least three steps are needed; the first one is the monomer polymerization, the second one is the surface modifi-cation of the nanoparticle and the third is the melt processing to mix the matrix and the nanoparticle. However the in situ polymerization approach, used in this work, is a one-step process because the clay is present in the medium during the polymerization. This technique allows decrease the operational cost and accomplish nanocomposites with better dispersions of the nanoclay in the polypropylene matrix. The aim of this work is the synthesis and characterization of polyethylene/sepiolite nanocomposites with improved properties, using the in situ polymerization approach, which can replace polyethylene composites commonly used in automotive. In situ polymerization processes allow producing materials with specific properties. The final proper-ties of the polyethylene/sepiolite nanocomposites depend on the polymerization time, on the catalyst, and on the amount of nanoclay. This article focuses on the study of these parameters, since by con-trolling them, and thus the stereoselectivity, the final properties for the material are defined.

90


Abstract ID-36

MuLTI SCALE MODELLInG OF GRAPHEnE PLATELETS REInFORCED POLYMER MATRIX COMPOSITE MATERIALS

Wiyao Azoti, Ahmed Elmarakbi

University of Sunderland, United [email protected], [email protected]

KEywORDS: graphene platelets, mean field homogenisation, finite element simulation

SUmmaRy: The derivation of the effective properties of graphene platelets based polymer composite materials is analysed in this work. For that purpose, a multi scale strategy embedding the constitutive law of each phase is accounted for through a comprehension mean-field technique for obtaining the mechanical properties. Analytical as well as finite element techniques are employed to derive the ove-rall response for a macroscopic structural application. Indeed, a starting point of such a modelling is given by the mechanical properties of the graphene sheets. They are considered as platelets embedded within a rate-independent elasto plastic matrix phase. The composite response is therefore computed under a boundary value problem by applying static or kinematic admissible loading. Mean field ho-mogenisation scheme for instance the Mori-Tanaka is used to obtain the overall response for different spatial orientation (aligned 2D, random 3D) configurations of graphene platelets in terms of Young’s modules, Poisson’s ratio, shear modules, bulk modulus of graphene composites. Several design parame-ters like the 2D versus 3D graphene orientation as well as the uniform graphene sizes versus different graphene sizes and the aspect ratio (AR) effects are investigated with respect to the overall response of the composite.

91


Abstract ID-42

HIERARCHICAL MODELLInG OF CARBOn FIBRES GRAPHEnE REInFORCED POLYMER COMPOSITES MATERIALS

Hicham El-Hage(1), Mustapha El Kady(1), Ahmed Elmarakbi(2), Wiyao Azoti(2)

(1)Lebanese International University, [email protected], [email protected]

(2)University of Sunderland, United [email protected], [email protected]

KEywORDS: Hierarchical modelling, carbon fibres, graphene reinforced polymer composites ma-terials

SUmmaRy: Graphene based nanocomposites are widely used for enhancing the multifunctional res-ponse of composite materials. This work aims to investigate the mechanical response of a hierarchical carbon fibres graphene reinforced polymer composite materials using a combined finite element FE and analytical multiscale approaches. Firstly, a FE analysis derives the effective properties of the gra-phene polymer composite through a representative volume element RVE. Indeed, the atomic structure of the graphene is represented as beams elements. The modified Morse potential is used with mole-cular structural mechanics to provide the graphene sheets with in-plane and out-of-plane mechanical properties. The interface which is governed by physico-chemical interactions through non covalent bonds Van-der-Walls liaisons is modelled by non-linear springs elements based on the Lennard-Johns interatomic potential. The polymer matrix phase is implemented as a nonlinear ductile damage mate-rial via a used defined subroutine UMAT. Next, the corresponding FE homogenised properties is used in subsequent micromechanical analysis to predict the mechanical response of the graphene polymer composite as well as the graphene carbon fibre polymer hierarchical composite. For such a purpose, the generalised method of cells (GMC) mi-cromechanics theory is used to derive the next higher length-scale predictions.

92


Abstract ID-44

MECHAnICAL PROPERITES OF A THERMOPLASTIC ADHESIVE MODIFIED WITH GRAPHEnE nAnOPLATELETS

FOR AuTOMOTIVE APPLICATIOnS.

Raffaele Ciardiello(1), Giovanni Belingardi(1), Brunetto Martorana(2), Francesco Cristiano(3), Francesco Bertocchi(3), Valentina Brunella(4), Marco Zanetti(5)

(1)Politecnico di Torino, [email protected], [email protected]

(2)Centro Ricerche Fiat, [email protected]

(3)Nanesa, [email protected], [email protected]

(4)Università di Torino, [email protected]

(5)University of Torino, [email protected]

KEywORDS: Vehicle lightweight design, Reversible adhesive joint, Graphene nanoplatelet, Ther-moplastic adhesive, Mechanical properties

SUmmaRy: The potential use of exfoliated graphite nanoplatelets have been explored in many areas of science and engineering due to its unprecedented chemical, physical and mechanical properties.The interest for the use of this kind of graphene has increased in car industry sector in the last years, to take advantage from the peculiar properties of this innovative material. As a consequence, among the different use of graphene, we have started to explore its application as filler for thermoplastic structural adhesives. The motivations have to be found in the possibility to take advantage of its electro-magnetic properties in order to melt the adhesive layers used to bond parts made by different materials, by using electromagnetic induction or microwave. In this way, the vehicle components can also be disassembled with benefits in terms of repairing and recycling at the end-of-life. Although this additional property could be used to melt the adhesive, the addition of fillers in an adhesive matrix might lead to a modification of its mechanical properties. For these reasons in this work a polyolefin based thermoplastic adhesive has been modified with graphene nanoplatelets in order to investigate the induced changes in its mechanical properties. Performed Single Lap Joint (SLJ) tests show a significant enhancement of mechanical properties, in particular of the ultimate strength, of this nanomodified adhesive compared to the pristine adhesive. The obtained results have been compared with those obtained with the same adhesive modified by addition of ferrite or magnetite particles. Further the joint separation surfaces have been analysed and compared in order to show similarities and differences among the use of the different fillers.

93


Abstract ID-46

MuLTISCALE AnALISYS OF THE MECHAnICAL PERFORMAnCE IMPROVEMEnT OF COMPOSITES CFRP LAMInATES,

AnD COMPOSITES WITH SHORT GLASS FIBERS, THROuGH THE ADDITIOn OF nAnOPLATLETS OF GRAPHEnE

Ahmed Elmarakbi(1), Matteo Basso(2)

(1)University of Sunderland, United [email protected]

(2)Centro Ricerche Fiat, [email protected]

KEywORDS: Graphene NanoPlatelets, Debonding, Interlaminar Shear Strength, Fracture Tough-ness, Improve Mechanical Chracteirstics

SUmmaRy: In this work it is described the analisys of the behavior of polymeric composites reinfor-ced with short glass fibers and unidirectional carbon fibers when the matrix was functionalized with Graphene NanoPlatelets (GNP). The graphene nanoplatelets dispersed in a matrix (thermoplastic or thermoset), I can be able to improve in general the strength of materials and the resistance to crack pro-pagation (Fracture Toughness). In particular, for the CFRP laminates, could improve the resistance to delamination (Interlaminar Shear Strength). In fact , between two adjacent plies of the laminate there is only the matrix and so the delamination resistance depend only by the dispersed Graphene that can improve the fracture and strength of the matrix. This investigation it was conduct through the use of Analisys Micromechanics tools and typical software’s for the structural simulation of the component at macro scale. Some experimental results were used for the validation of the simulations.

94


Abstract ID-50

THERMAL AnD ELECTRICAL PROPERTIES OF GRAPHEnE-BASED THERMOSET COMPOSITES: A STuDY On THE ROLE OF GRAPHEnE

nAnO-PLATELETS MORPHOLOGY

Nicola Mirotta(1), Alessandro Kovtun(1), Emanuele Treossi(1), Alberto Fina(2), Julio Gomez(3), Tamara Blanco(4), Vincenzo Palermo(1)

(1)Cnr isof, [email protected], [email protected], [email protected], [email protected]

(2)Politecnico di torino, [email protected]

(3)Avanzare, [email protected]

(4)Airbus, [email protected]

KEywORDS: Graphene-composite, Thermoset, Aeronautics

SUmmaRy: Graphene reinforced polymer composites show important improvements in their elec-trical and thermal conductivity and other thermo-physical properties, as compared to other more con-ventional materials. One of the main challenges to achieve the large-scale potential for technological and engineering applications is to achieve homogeneous dispersion of the thin gra-phene nano-platelets (GNPs) within the polymer matrix. In this work, a combination of various te-chniques has been used to prepare well-dispersed and well-performing graphene/epoxy composites, exploiting to achieve efficient mixing shear micromechanical forces with high shear-speed mixing follo-wed by a calendering technique. The fabrication method for epoxy composites is quite simple, based on mechanical mixing using a combination of different techniques following by casting in a metallic mould. A main advantage in this technique is the absence of volatile and harmful solvent as carrier for a filler. Two different graphene nano-platelets (GNPs), with different thickness and flake size, were added in order to analyse the influence of the size of the nano-filler: thickness and lateral dimensions. Various amounts of graphene ranging from 0% to 2% w/w were added to the composite. Electrical conductivity measurements were performed on macroscopic samples (7 cm) and present the typical percolative behavior, with a strong dependence of conductivity on filler’s morphology.

95


Abstract ID-59

IMPROVEMEnT OF InTERLAMInAR MECHAnICAL PROPERTIES OF CFRP LAMInATES BASED

On nAnOFILLER InTERFACE REInFORCEMEnT

Ning Hu, Huiming Ning, Jianyu Zhang

Chongqing University, [email protected], [email protected], [email protected]

KEywORDS: Carbon fiber reinforced plastic laminates (CFRP) Nanofiller interleaf, Fracture tou-ghness, Interlaminar mechanical properties

SUmmaRy: With excellent in-plane mechanical properties, Carbon fiber reinforced plastic (CFRP) laminates have been widely used in many structural engineering fields. However, their out-plane i.e. interlaminar mechanical properties are relatively poor. To solve this problem, improvement of inter-laminar mechanical properties in CFRP laminates based on nanofiller interleaf reinforcement was systematically investigated in this study. Carbon black and graphene oxide were employed as reinforce-ment interleaves to insert into the interlaminar interface of CFRP laminates by solution method. The influences of different kind and addition of nanofillers on mode I and mode II fracture toughness and resistance of CFRP laminates were extensively explored by the double cantilever beam (DCB) and end notched flexure (ENF) tests. It is shown that, with 15 g/m2 carbon black addition, the mode I fracture toughness and resistance of CFRP laminates were increased significantly, which were 50.3% and 88.6% higher than that of the plain specimen. By incorporating 10 g/m2 carbon black at the inter-face of CFRP laminates, the CFRP laminates demonstrated the highest Mode-II fracture toughness, which was 145% higher than those of pristine CFRP laminates. When graphene oxide was added into the interface of CFRP laminates, it is found that graphene oxide is more effective for improving the interlaminar mechanical properties of CFRP laminates than carbon black. The specimens with 2 g/m2 graphene oxide addition possess the highest Mode I fracture toughness and resistance, i.e., 170.8% and 108% increases compared to that of the plain specimen respectively. To uncover the improvement mechanisms, crack propagation and fracture surface have also been observed by optical and scanning electron microscopies.

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