The potential of direct-adhesion polymer metal hybrid (PMH) technology for use in load-bearing structural automotive components is explored computationally. Multi-disciplinary computations are carried out ranging from computational fluid mechanics of injection mold filling and packing processes, flow-induced fiber orientation analysis, visco-elastic analysis of in-cavity residual stress developments and structural-mechanics computation of injection molded part warping (under the effect of residual stresses) and deflection under simulated thermal loading encountered in the paint shop and under mechanical in-service loading. The results obtained helped identify the minimum level of polymer-to-metal adhesive strength (exceeding 10 MPa) and an optimal PMH component architecture which are required in order for the direct adhesion PMH technology to be considered a viable (weight-saving, parts consolidation, manufacturing process-chain compatible) alternative to the currently used PMH technology.
Computational feasibility analysis of direct-adhesion polymer-to-metal hybrid technology for load-bearing body-in-white structural components
Rechnergestützte Machbarkeitsuntersuchung der Direkthaftungs-Hybridtechnologie von Polymeren auf Metallen zur Herstellung tragender Karosserieteile
Journal of Materials Processing Technology ; 195 , 1-3 ; 282-298
2008
17 Seiten, 9 Bilder, 5 Tabellen, Quellen
Article (Journal)
English
Schichtwerkstoff , Polymerbeschichtung , Hybridverbundwerkstoff , Stahlblech , Stahlblechkarosserieteil , Spritzgussteil , Spritzgießverfahren , In-Mold-Beschichten , Haftfestigkeit , Machbarkeitsuntersuchung , rechnerunterstützte Simulation , tragendes Bauteil , numerische Strömungssimulation , Gießformfüllen , Faserorientierung , Visioplastizität , Eigenspannung , mechanische Spannungsverteilung , Spannungsanalyse , Verzug , thermische Verformung , Verfahrenseignung , Prozessoptimierung , gefüllter Verbundwerkstoff , Polyamid 6 , glasfaserverstärkter Kunststoff