The production of Fiber Reinforced Plastics (FRP) has been extensively researched with the aim of achieving light weighting targets while also reducing process costs through efficient material usage. Combining modern and traditional manufacturing techniques and leveraging the advantages of their design freedom could be highly beneficial in achieving the aforementioned targets. This study examines the potential combination of metallic 3D printing and Tailored Fiber Placement (TFP) technology with the goal of developing a new manufacturing process for fiber-reinforced composites. The current research paper focuses on the simulation and testing of this established manufacturing process. The 3D printed metallic insert acts as a load introduction element and is surrounded by TFP preforms, which are optimized for load path. These inserts after assembled with the TFP preforms was infiltrated with resin and cured to produce the demonstrators and test specimen using Resin Transfer Molding (RTM) process. Static finite element simulations and Voxel-based 3D topology optimization were used to identify the load transfer path and derive the fiber placement path for TFP process for four simple load cases like tension, compression, bending and torsion. Topology optimization was also used to derive different insert designs. This paper focuses solely on simulation, optimization, and –final TFP pre-form production for tensile test specimen production. The effectiveness of various insert designs and fiber combinations will be rigorously evaluated through experimentation. The collected data will be analyzed, interpreted, and ultimately presented in a forthcoming publication.
Optimizing Metal-Composite Joints: 3D-Printed Inserts and Tailored Fiber Placement
International Commercial Vehicle Technology Symposium ; 2024 ; Kaiserslautern, Deutschland March 13, 2024 - March 14, 2024
Commercial Vehicle Technology 2024 ; Chapter : 7 ; 123-138
2024-10-02
16 pages
Article/Chapter (Book)
Electronic Resource
German
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