Abstract
Rotational molding constitutes a promising manufacturing technology for rotationally symmetric components made of thermoset matrix with continuous fiber reinforcement. The present study deals with the numerical analysis of a rotationally molded composite tie rod with metallic load introduction elements. For this purpose, the adhesive joint between carbon fiber reinforced plastic and metallic load introduction element was investigated in more detail. Different geometries of a spew fillet were evaluated to reduce the stress peaks occurring at the ends of the overlap. A design of experiments was used to determine the influence of the different parameters. An optimized geometry was derived and compared with a reference in terms of stress distribution. Subsequently, test specimens were rotationally molded and mechanically tested. The results of the study show that the maximum stresses within the adhesive layer can be reduced with an optimized spew fillet, and thus a higher mechanical tensile load of the composite tie rod can be achieved.
Highlights
Tie rods and drive shafts are used in many technical applications to transmit forces and torques, for example as actuators for landing flaps in aircraft applications or drive shafts in automotive applications
As expected from the numerical results, the effect of the spew fillet is less significant for Variant 2 (V2) than for Variant 1 (V1), V2 has the higher maximum tensile strength due to its high axial stiffness
The complete spew fillet of matrix remains on the side of the carbon fiber reinforced plastic (CFRP) body at failure and only a few smaller particles break out of the surface and stick to the load introduction element
Summary
Tie rods and drive shafts are used in many technical applications to transmit forces and torques, for example as actuators for landing flaps in aircraft applications or drive shafts in automotive applications. Compared to conventional metal components, the use of carbon fiber reinforced plastic (CFRP) can increase the strength and stiffness of the component while reducing its weight. In the case of a tie rod, the energy consumption of a moving system can be reduced, and the payload increased [1]. With a CFRP drive shaft, a higher bending-critical rotational speed can be achieved due to the higher specific stiffness [2]. These components are often part of a larger structure made of a metallic material. The components are generally designed with a cylindrical body made of CFRP and metallic load introduction elements, which are connected to the rest of the bodywork
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