Hybrid manufacturing of a 3D-shaped fiber metal laminate

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes Pub Date : 2025-04-22 DOI:10.1016/j.jmapro.2025.04.031

Matthias Merzkirch , Erwan Juin , Jesper Eman , Jocke Pettersson , Magdalena Juntikka , Fredrik Ahlqvist , Olof Säfvenberg

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引用次数: 0

Abstract

This contribution presents a methodology for designing, manufacturing, and testing of a multi-material solution demonstrator of a lower control arm for electric vehicle (EV) chassis made of a three-dimensional Fiber reinforced polymer-Metal Laminate (FML). The Integrated Computational Materials Engineering (ICME) approach includes simulation methodology for process modeling, i.e. forming and draping, and part performance with the aim to reduce the developing time and related trial and errors.

The challenges, besides a limited availability of resources and material input data for numerical models, include the combination of different forming methods for Glass Fiber Reinforced Polymers (GFRP) and sheet metals (aluminum alloy) with the aim of simultaneous forming of both materials. Especially the sheet metal forming needed several improvement steps regarding heat treatment state to increase the ductility and reduce crack propagation, as well as optimization of the shape of the blanks to be formed into an asymmetric, three-dimensional geometry. Assembly includes adhesive bonding of the flat FML to the curved structure, and adapters for the testing to be performed. The quasi-static misuse testing is in good agreement to the results obtained from the simulated structural performance, with the weakest location being the adhesive bond line. An outlook on potential improvements regarding process simulation for manufacturing Fiber Metal Laminates, including necessary input data, is provided.

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3d形状纤维金属层压板的混合制造

本文提出了一种由三维纤维增强聚合物-金属层压板（FML）制成的电动汽车（EV）底盘下控制臂的多材料解决方案演示器的设计、制造和测试方法。集成计算材料工程（ICME）方法包括过程建模的仿真方法，即成形和悬垂，以及零件性能，旨在减少开发时间和相关的试验和错误。除了有限的可用资源和用于数值模型的材料输入数据外，挑战还包括玻璃纤维增强聚合物（GFRP）和金属板（铝合金）的不同成型方法的组合，目的是同时成型两种材料。特别是在板料成形过程中，需要对热处理状态进行若干改进步骤，以提高塑性，减少裂纹扩展，并将待成形坯料的形状优化为非对称的三维几何形状。装配包括将平面FML粘接到弯曲结构上，以及用于进行测试的适配器。准静态误用试验结果与模拟结构性能结果吻合较好，最弱的位置是粘接线。展望了金属纤维层压板制造过程模拟的潜在改进，包括必要的输入数据。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-

CiteScore

10.20

自引率

11.30%

发文量

833

审稿时长

50 days

期刊介绍： The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.