Technologies for economic and functional lightweight design: Conference proceedings 2020 (Zukunftstechnologien für den multifunktionalen Leichtbau)

This book comprises the proceedings of the conference “Future Production of Hybrid Structures 2020”, which took place in Wolfsburg. The conference focused on hybrid lightweight design, which is characterized by the combination of different materials with the aim of improving properties and reducing weight. In particular, production technologies for hybrid lightweight design were discussed, new evaluation methods for the ecological assessment of hybrid components were presented and future-oriented approaches motivated by nature for the development of components, assemblies and systems were introduced. Lightweight design is a key technology for the development of sustainable and resource-efficient mobility concepts. Vehicle manufacturers operate in an area of conflict between customer requirements, competition and legislation. Material hybrid structures, which combine the advantages of different materials, have a high potential for reducing weight, while simultaneously expanding component functionality. The future, efficient use of function-integrated hybrid structures in vehicle design requires innovations and constant developments in vehicle and production technology. There is a great demand, especially with regard to new methods and technologies, for "affordable" lightweight construction in large-scale production, taking into account the increasing requirements with regard to variant diversity, safety and quality. Contents Innovative and Smart Production Life Cycle Assessment of Thermoplastic Hybrid Structures with Hollow Profiles Abstract. 1 Introduction 2 Functionalised Thermoplastic Hollow Profile 3 Process Chain 3.1 Sub-process 1: Production of the Hollow Profile 3.2 Sub-process 2: Combination and Functionalisation via Injection Moulding 4 Determination of the Ecological Potential 5 Conclusion and Evaluation of the Process Efficiency References Interdisciplinary Research for the Development and Realization of a Structural Component in Multi-Material Design Suitable for Mass Scale Production Abstract. 1 Introuction 2 Development and Production of a Hybrid Prototype Structure 2.1 Coil-based Hybrid Semi-finished as a Basis for Manufacturing of Hybrid Parts 2.2 Load-Path-Compatible Material Combination and Functional Integration Through Multi Material Design 2.3 Plant Layout and Tool Structure for Investigation of a Fully Automated Manufacturing Process for Hybrid A-pillar Reinforcement Prototype 2.4 Process Sequence of the Hybrid A-pillar Reinforcement Prototype 3 Conclusion and Further Research References Net Shape Stacking and Consolidation of Thermoplastic Composite Tapes Abstract. 1 Introduction 2 State of Research an Applications 3 Investigations and Results 3.1 Processing Sequence Employing Injection Moulding 3.2 Tape Stacking with Pick-&-Place 3.3 Consolidation with Heating-&-Cooling 4 Conclusions and Outlook References Thermoset Technologies for Cost Efficient Production of Lightweight Composites Abstract. 1 Introduction 2 HP-RTM Processing of Composite Leaf Springs 3 In-mold Coating for High Volume Production of Class A Surfaces 4 Phenolic Sheet Molding Compound for Battery Enclosures 5 Conclusion References Factories of the Future Contribution to Digital Linked Development, Manufacturing and Quality Assurance Processes for Metal-Composite Lightweight Structures Abstract. 1 Introduction 2 Concept of an MMD-based Engineering Process Model 3 Exemplary Application of a Preliminary Design 4 Validation Steps in Early Stages of the Development Process 5 Conclusion References Thinking Innovation Ahead – Joint Semantic Modelling for Integrated Product and Production at the Research Campus Arena2036 Abstract. 1 Introduction – A Titan of Research 2 Forethought Instead of Hindsight 2.1 Questions Instead of Answers 3 Joint Research Activities to Gain Synergies in Automotive Production 3.1 Joint Semantic Modeling for I4.0 Component Description 3.2 Cyber-Physical Production Systems 3.3 Cyber-Physical Product Design 3.4 Technology Transfer to an All-New Modular, Cyber-Physical Vehicle Concept FlexCAR 4 Concluding Remarks – The Missing Link 5 Sumary and Outlook References Integrated Factory Modelling – Enabling Dynamic Changes for the Factory of the Future at the Example of E.GO Mobile AG Abstract. 1 Introduction 2 State of the Art 2.1 Factory Planning 2.2 The Subject: Factory 2.3 Digital Factory Planning 3 Integrated Factory Modelling 4 Outlook References Life-Cycle Engineering Methodology for Assessing the Environmental Impact of Emerging Materials Abstract. 1 Introduction 2 State of Research 3 Proposed Methodology 4 Exemplary Application 5 Discussion of the Methodology and Its Application 6 Conclusion & Outlook References Systematic Design of Body Concepts Regarding Mini-Mal Environmental Impacts in an Early Concept Phase Abstract. 1 Introduction 2 State of Research 3 Conceptual Design of Body Concepts Regarding Minimal Environmental Impacts 3.1 Design Method 3.2 Application of the Optimization Procedure 4 Verification of the Concept by Means of a Case Study 5 Conclusion References Processing Capabilities for Thermoplastic Composites – Minimum Material Consumption and Recyclability ABSTRACT. 1 Introduction 2 State of Research an Applications 3 Investigations and Results 3.1 Processing of Thermoplastic Composite Blanks 3.2 Indicators for Performance Characteristics 3.3 Variable Thickness of the Composite Within the Same Part 3.4 Combination of Horizontal and Vertical Infrared Ovens 3.5 Machinery, Mould, and Automation 3.6 Recyclability of Thermoplastic Composite Materials 4 Conclusions and Outlook References Generative Manufacturing Evaluation of Technologies for the Fabrication of Continuous Fiber Reinforced Thermoplastic Parts by Fused Layer Modeling Abstract. 1 Introduction 2 Technologies for the Production of Continuous Fiber Reinforced Thermoplastics Using FLM 3 Experimental Methodology 3.1 Process Parameters 3.2 Tensile Test 3.3 Bending Test 4 Results 4.1 Result Tensile Test 4.2 Result Bending Test 5 Conclusions References Design of Additively Manufactured Heat-Generating Structures Abstract. 1 Introduction 2 State of Research 3 Experimental Set-Up for Additive Manufacturing of Test Specimens 4 Results of Specific Regression Model of Resistivity 4.1 Material-Specific Regression Windows 4.2 Coefficient Table of the Average Resistivity 5 Application 6 Conclusion References Process Simulation for Screw Extrusion Additive Manufacturing of Plastic Parts Abstract. 1 Introduction 2 Methodology 2.1 Modelling of Bead Deposition 2.2 Estimation of Manufacturing Time 3 Results 3.1 Prediction of Bead Shape 3.2 Influence on Manufacturing Time 4 Conclusion References Bio-based Innovations Biomimetic Soft Robotic Peristaltic Pumping System for Coolant Liquid Transport Abstract. 1 Introduction 2 Characterization of the Silicone Based Biomimetic Peristaltic Pump (SBPP) 3 Discussion 4 Conclusions References Biomimetic Suction Cups for Energy-Efficient Industrial Applications Abstract. 1 Introduction 2 Suction Adhesion in Biological and Biomimetic Structures 3 Transfer into Suction Cups for Industrial Applications 4 Conclusion and Outlook References Bio-Sourced Artificial Leather for Interior Automotive Applications Abstract. 1 Introduction 2 Materials and Methods 2.1 Vegan Biosourced Imitation Leather 2.2 Waterborne Polyurethane Imitation Leather 2.3 Woodfoam 3 Results and Specification 3.1 Waterborne PU-Material 3.2 Wood Foam 4 Conclusion and Outlook References Functional Structures Continuous Profile Production with Hybrid Materials by Pultrusion Abstract. 1 Introduction 2 Materials 2.1 Components of the Fiber-Reinforced Plastics 2.2 Metallic Component and Powder Coating 3 Specimen Manufacturing 3.1 The Pultrusion Process 3.2 Manufacturing of Specimen by Pultrusion 4 Test, Results and Discussion 4.1 Optical and Non-Destructive Analysis of the Complete Composite System 4.2 Specimen Preparation and Lap Shear Test 4.3 Results of the Lap Shear Test and Discussion 5 Pultrusion of a Hybrid Side Sill 6 Conclusion and Outlook References Comparison of the Mechanical Properties of Adhesively Bonded and Mechanically Interlocked Steel/Fibre-Reinforced Thermoplastic Hybrids Produced Using One-Step Forming Process Abstract. 1 Introduction 2 Experimental Procedure 3 Results 4 Conclusion References Thin Film Sensor Systems for Use in Smart Production Abstract. 1 Introduction 2 Thin Film Sensor and Diaforce®-Layer System 3 Characteristic Resistance Dependencies of Thin Film Sensor Structures 3.1 Thermoresistive Temperature Sensors on Injection Mold Inserts 3.2 Piezoresistive Force Sensors for Forming Tools 4 Application Examples for use in Smart Manufacturing 4.1 Sensory Tool for Sheet Bending Processes 4.2 Sensory Module for Deep Drawing Processes 4.3 Injection Molding Sensor Inserts 4.4 Smart Washer System 5 Summary and Outlook References Radomes – Process Influences on the Integration of Radar Sensors Abstract. 1 Introduction 2 Materials and Methods 3 Results 4 Summary and Outlook References Reports from the Research Clusters Fiber Orientation Evaluation of Intrinsically Manufactured Metal-CFRP Hybrid Structures by Data Fusion of Pulsed Phase Thermography and Laser Light Section Abstract. 1 Introduction 2 State of the Art 2.1 Laser Light Section 2.2 Thermography 2.3 Data Fusion of Laser Light Section and Thermography 2.4 Fiber Orientation Analysis 3 Hybrid Specimen Design 3.1 Demonstrator 3.2 Integration of Representative Defects 4 Evaluation of 3d Fiber Orientation 4.1 Parameter Settings of the Multi-sensor System 4.2 Algorithm for Fiber Orientation Analysis 4.3 Results 5 Conclusion and Outlook References Combined External and Internal Hydroforming Process for Aluminium Load Introduction Elements in Intrinsic Hybrid CFRP Contour Joints Abstract. 1 Introduction 2 Design of Multi-Scale Structured Load Introduction Elements 3 Two-Stage Hydroforming Process of Load Introduction Element 3.1 Process Simulation of Meso Structuring 3.2 Tool and Process Development 3.3 Experimental Validation 4 Conclusion References Mesoscale Surface Structures in CFRP-Metal-Hybrid Joints – Aspects of Design and Manufacturing Abstract. 1 Introduction 2 State of the Art 3 Simulation of Forced Demoulding Deformations Through Undercut 4 Experimental Ejection Tests 5 Results and Evaluation 6 Conclusion References Nondestructive and Destructive Testing on Intrinsic Metal-CFRP Hybrids Abstract. 1 Introduction 2 Intrinsic Metal CFRP Hybrids 3 Infrared Thermography 4 Electromagnetic Acoustic Transducer (EMAT) 5 Results 6 Conclusion References Resistance Welding of FRP to Steel Components in High-Volume-Production Abstract. 1 Introduction 2 Materials and Methods 3 Experiments 3.1 Mechanical Characterization of the Joint 3.2 Investigation of Component-Like Structures 3.3 Combination of the Innovative Welding Method with Bonding Processes 4 Conclusion References Novel Ultrasonic-Based Joining Methods for Metal-Plastic Composites (MPC) Abstract. 1 Introduction 2 Novel Joining Concept 3 Ultrasonic Heating and Displacement – Proof of Concept 4 Material Characterization 5 FE Modeling 5.1 Ultrasonic-Assisted Displacement of the Core Layer 5.2 Joining Processes 6 Results of Suppressing Tests 7 Conclusion References Experimental Parameter Identification for the Bending Based Preforming of Thermoplastic UD-Tape Abstract. 1 Introduction 2 Kinematic Description of the Forming Movement 3 Process Parameters and Influencing Factors 4 Summary and Outlook References Design and Simulation Development of a Hybrid Crash-Relevant Car Body Component with Load-Adapted Thickness Properties: Design, Manufacturing and Testing Abstract. 1 Introduction 2 Proposed Optimization Method for Tailored Hybrid Stacks 2.1 Parametrized Bi-linear Multi-Material Approach 2.2 Optimization Methodology 3 Reference Structure Benchmark 4 Component Optimizations 4.1 Layer Design 4.2 Component Design 5 Component Manufacturing and Testing 5.1 Manufacturing 5.2 Crashworthiness 6 Discussion 7 Conclusions References Operationalization of Manufacturing Restrictions for Hybrid Tailored Forming Components Abstract. 1 Introduction 2 Interfacial Zone Evolutionary Optimization—IZEO 3 Suspension Arm and Required Manufacturing Processes 4 Applying IZEO for the Suspension Arm 5 Comparison of Hybrid Suspension Arms with and Without Manufacturing Restrictions 6 Conclusion References A New Numerical Method for Potential Analysis and Design of Hybrid Components from Full Vehicle Simulations: Implementation and Component Design Abstract. 1 Introduction 2 Proposed Approach 2.1 Uniaxiality Analysis 2.2 Uniaxiality-Weighted Sensitivity Analysis 3 Accumulated Uniaxiality Analysis 4 Component Design 4.1 Component Selection 4.2 Component Design 4.3 CO2 Footprint and Cost Analysis 4.4 Full Vehicle Validation 5 Component Manufacturing and Testing 6 Conclusions References Graph Based Algorithms to Enhance Mid-Surface Design Fidelity of Finite Element Models of Extrusion Profiles Abstract. 1 Introduction 2 Algorithms to Enhance Mid-Surface Design Fidelity 2.1 Graph Syntax and Translation into Finite Element Model 2.2 Algorithm to Apply Rounded Corners 2.3 Algorithm to apply material accumulations 3 Application of Algorithms on Structures in Crash Load Cases 3.1 Rocker Pole Impact (Lateral Load Case) 3.2 Drop Hammer Impact (Axial Load Case) 4 Conclusion References Author Index