Abstract
Beads are widely used to stiffen sheet metal components subjected to bending loads. Often, these bead-stiffened parts are used in product variants that differ significantly in the amount of acting loads. Lamination of unidirectional carbon fibre reinforced plastic (UD-CFRP) on the top flange area of individual beads represents a method for further increasing weight-specific stiffness: By varying the number of plies, a specifically configured component is obtained for each of the load cases. As a result, no changes to the forming tools are necessary and a minimum amount of the UD-CFRP material is required. In this work, a complete manufacturing process for a fibre reinforced bead was developed: First, a bead cross section geometry with an adapted top flange area to accommodate the UD-CFRP plies was designed and stamped into pre-stretched sheet samples of DX56 steel. Subsequently, the suitability of several surface pre-treatment processes to achieve sufficient bond strength of the composite bead was experimentally investigated and the UD-CFRP plies were applied by lamination. Final bending tests quantified the achievable stiffening effect of the investigated bead variants, showing a significant increase of the maximum supportable load compared to the standard non-reinforced cross-section.
Highlights
In order to meet customer-specific requirements, products appear in multiple variants, often showing high mass differences
Lamination of unidirectional carbon fibre reinforced plastic (UD-CFRP) on the top flange area of individual beads represents a method for further increasing weightspecific stiffness: By varying the number of plies, a configured component is obtained for each of the load cases
The suitability of several surface pre-treatment processes to achieve sufficient bond strength of the composite bead was experimentally investigated and the UD-CFRP plies were applied by lamination
Summary
In order to meet customer-specific requirements, products appear in multiple variants, often showing high mass differences. In the automotive industry these can amount to more than 500 kg within a series [1]. A uniform design of individual product components with respect to the peak-loaded variant leads to over-dimensioning of the lower-loaded variants, which counteracts cost and lightweight design objectives. One possible solution is to create variants at the component level. When sheet metal forming processes are used, cost-intensive adjustments to the forming tools are necessary. This makes the design variants uneconomical, especially for parts with low volumes [2]. For components subjected predominantly to bending loads, a hybrid material approach for generating cost-
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