On the bead design in LFT structures: the influence of manufacturing-induced residual stresses

Abstract In the design of long fibre reinforced thermoplastic (LFT) structures, there is a direct dependency on the manufacturing. Therefore, it is indispensable to integrate the manufacturing influences into the design process. This not only offers new opportunities for material- and load-adapted designs, but also reduces cost-intensive modifications in later stages. The goal of this contribution is to make the complexity manageable by presenting a method which couples LFT manufacturing and structural simulations in an automated optimization loop. Herein, the influence of linear-elastic, local anisotropic material properties as well as residual stresses resulting from the compression molding of LFT on the stiffness-optimized design of beaded plates is investigated. Based on the simulation studies in this contribution, it can be summarized that the resulting bead height and flank angle, considering anisotropies and residual stresses, are smaller compared to isotropic modelling. As a conclusion, the strength constraint limits the maximum bead height and the flank angle needs to be additionally chosen as a consequence of the local fibre orientations and residual stresses resulting from manufacturing. Optimized bead cross sections are only valid for a specific system under investigation, as they depend on the defined boundary conditions (load case, initial charge geometry and position, fibre orientations, etc.).