Manufacturing of a UD-Tape Reinforced Hybrid Thermoplastic Composite Test Component
B. Rietman, E. Boxus, S.M. Kashif, N. Verghese
SABIC, Geleen, The Netherlands
The regulations for reduction of fleet emissions stimulate the increasing use of lightweight materials in the automotive industry. Continuous fibre reinforced plastics feature excellent mechanical properties combined with a low density. Thermoplastic composites, in which an engineering thermoplastic is used as the matrix material, additionally allow for fast processing cycles in the order of one minute. Although the inherent properties of thermoplastic composites principally match well to the requirements from industry confidence still seems to be lacking. The main reason is that the simulation methods for composite design are not yet matured and design data is not available.
To address the aforementioned needs a technology demonstrator has been designed with the goal of testing the failure limits of the used thermoplastic composites under different loading conditions on the component level.
By doing so, the developed simulation approaches for tensile, compression and shear failure, static as well as dynamic, were successfully validated. The test component consist of unidirectional (UD) tape based laminates overmoulded with a long fibre injection moulding grade. In the one-step fashion of the overmoulding process the insert is pre-heated to forming temperature, transferred to the mould, shaped by the closing stroke of the moulding tools and subsequently overmoulded. To investigate the manufacturability different composite inserts have been used, starting from UD strips towards full-width multi-directional laminates. Since the coherence of UD materials perpendicular to the fibre direction is poor, especially in melt state, dedicated clamping and fixation devices have been developed.
This paper addresses the main challenges in processing UD based laminates in an overmoulding cycle.
ITHEC 2016 Manuscript P25
Publication date: 01/10/2016
Manuscript P25 published in Conference Proceedings ITHEC 2016
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