Structure Design on Thermoplastic Composites Considering Forming Effects

Carbon fiber reinforced polypropylene (CF/PP) thermoplastics integrate the superior formability of fabrics with the recoverable characteristics of polypropylene, making them a pivotal solution for achieving lightweight designs in new energy vehicles. However, the prevailing methodologies for designi...

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Veröffentlicht in:Polymers 2024-10, Vol.16 (20), p.2905
Hauptverfasser: Xie, Wei, Song, Kai, Yang, Ju, Wang, Fengyu, Dong, Linjie, Jin, Shengjie, Zhu, Guohua, Wang, Zhen
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container_issue 20
container_start_page 2905
container_title Polymers
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creator Xie, Wei
Song, Kai
Yang, Ju
Wang, Fengyu
Dong, Linjie
Jin, Shengjie
Zhu, Guohua
Wang, Zhen
description Carbon fiber reinforced polypropylene (CF/PP) thermoplastics integrate the superior formability of fabrics with the recoverable characteristics of polypropylene, making them a pivotal solution for achieving lightweight designs in new energy vehicles. However, the prevailing methodologies for designing the structural performance of CF/PP vehicular components often omit the constraints imposed by the manufacturing process, thereby compromising product quality and reliability. This research presents a novel approach for developing a stamping-bending coupled finite element model (FEM) utilizing ABAQUS/Explicit. Initially, the hot stamping simulation is implemented, followed by the transmission of stamping information, including fiber yarn orientation and fiber yarn angle, to the follow-up step for updating the material properties of the cured specimen. Then, the structural performance analysis is conducted, accounting for the stamping effects. Furthermore, the parametric study reveals that the shape and length of the blank holding ring exerted minimal influence on the maximum fiber angle characteristic. However, it is noted that the energy absorption and crushing force efficiency metrics of the CF/PP specimens can be enhanced by increasing the length of the blank holding ring. Finally, a discrete optimization design is implemented to enhance the bending performance of the CF/PP specimen, accounting for the constraint of the maximum shear angle resulting from the stamping process. The optimized design resulted in a mass reduction of 14.3% and an improvement in specific energy absorption ( ) by 17.5% compared to the baseline sample.
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subjects Automobile industry
Behavior
Bending
CAE
Carbon fiber reinforced plastics
Component reliability
Composite materials
Computer aided engineering
Constraints
Design optimization
Energy absorption
Fiber composites
Fiber reinforced polymers
Finite element analysis
Finite element method
Hot pressing
Hot stamping
Laminates
Manufacturing
Material properties
Optimization
Polypropylene
Residual stress
Shape effects
Shear strain
Specific energy
Structural reliability
Textile composites
Thermoplastic composites
Thermoplastic resins
Yarn
Yarns
title Structure Design on Thermoplastic Composites Considering Forming Effects
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