Screening tests of an one-shot forming process of fibre-reinforced thermoplastics and steel sheets to determine the geometrical accuracyTuesday (28.04.2020) 12:00 - 12:20 Room 2
Due to the increasing demands for environmental protection, automotive manufacturers are striving to reduce fuel consumption and thus emission pollution. Therefore, their aim is not only to improve the efficiency of the powertrain but also to make the body in white lighter. In the high volume segment, the body in white mainly consists of deep drawn steels. Fibre-reinforced plastics (FRP), which possess a high specific strength and stiffness, are particularly suitable for lightweight design. However, due to high material costs and the lack of established joining processes the use of only FRP is not suitable for high volume production. In particular, fibre reinforced thermoplastics (FRTP) enable short cycle times, for instance in a thermoforming process. Therefore, FRTP are suitable for high volume production. By the combination of FRTP and steel for the manufacturing of hybrid components, material costs can be reduced in comparison to FRTP parts and established joining processes can be used. However, the process chain of manufacturing hybrid components consists of additional process steps. The integration of thermoforming and deep drawing processes enables a reduction of cycle time and a cost-efficient production. This paper presents a concept of a tool for an integrated thermoforming and deep drawing process. Based on the technological knowledge, the benefits and the challenges of the integration of both processes are explained and the requirements for the tool are derived. During the design process a thermal simulation is made to ensure an even heat distribution on the surface. Subsequently, the numerical results are validated with experimental heating tests on the tool. Finally, first hybrid forming tests are made and the influence of the process parameters on the product quality is investigated.