Title: Production and modelling of an intrinsic hybrid metal composite for automotive parts

Authors: Robert Kießling; Jörn Ihlemann; Matthias Riemer; Welf-Guntram Drossel

Addresses: Professorship of Solid Mechanics, Faculty of Mechanical Engineering, Chemnitz University of Technology, Reichenhainer Straße 70, Chemnitz 09126, Germany ' Professorship of Solid Mechanics, Faculty of Mechanical Engineering, Chemnitz University of Technology, Reichenhainer Straße 70, Chemnitz 09126, Germany ' Department Sheet Metal Forming, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, Chemnitz 09126, Germany ' Department Sheet Metal Forming, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, Chemnitz 09126, Germany

Abstract: Hybrid parts, which combine low weight with high strength, are moving in the focus of the automotive industry. This contribution deals with the development of an intrinsic hybrid composite made up of a continuous fibre-reinforced plastic, in which a metallic insert is integrated. The connection between these components is realised by a combination of adhesive bonding and a geometrical form fit. To this end, a metallic insert with form fit elements is developed. The form fit elements are generated by out-of-plane deformations induced by a global in-plane load. This in-plane load is applied within the global forming process. Consequently, the intrinsic hybrid composite is produced in an one-step process, which is presented as well. The mechanical properties of the resulting composite are analysed with the help of a finite element simulation of a representative volume element. In this context, inelastic material models at large strains, which are formulated based on directly connected rheological elements, are applied to take account of the mechanical behaviour of the individual components.

Keywords: aluminium alloy; automotive composite; fibre-reinforced plastics; finite element simulation; form fit element; hybrid composite; intrinsic production process; material modelling; multi-material system; rheological model.

DOI: 10.1504/IJAUTOC.2016.084325

International Journal of Automotive Composites, 2016 Vol.2 No.3/4, pp.209 - 228

Received: 02 Sep 2016
Accepted: 29 Jan 2017
Published online: 05 Jun 2017 *

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