Abstract
Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly functionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of overmoulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.
Highlights
Introduction published maps and institutional affilDue to the high demand for technical products in terms of their ecological and economic efficiency, lightweight design is one of the key technologies for achieving current and future goals in the field of energy revolution
The bond strength values and determined in the cross tension-test this section, the results of the experimental numerical investigations are preare analysed with regard to different manufacturing settings
The bond strength values determined in the cross tension-test results and the with model basedtocomputed values for autohesion, contact, bond are analysed regard different manufacturing settings.intimate
Summary
Introduction published maps and institutional affilDue to the high demand for technical products in terms of their ecological and economic efficiency, lightweight design is one of the key technologies for achieving current and future goals in the field of energy revolution. In addition to lightweight alloys, fibre-reinforced plastics (FRP) are increasingly being used in automotive [2,3] or aerospace [4,5] applications. Geiger and Ehrenstein [6] demonstrated the potential of a hybrid material combination on different cross beams. In this case, the bending and torsional strength of a hybrid beam was increased by using FRP and overmoulded plastic ribs when compared to a metal-plastic solution. The use of fibre-reinforced plastics and hybrid materials has economic and ecological challenges in markets that have to supply high manufacturing volumes, for example, the automotive industry. For the manufacturing of hybrid components with fibre-reinforced plastics in combination with iations
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
