journal article·2013-12

Thermoplastic Composites Reinforced with Textile Grids: Development of a Manufacturing Chain and Experimental Characterisation

R. Böhm, E. Hufnagl, R. Kupfer, T. Engler, J. Hausding, C. Cherif, W. Hufenbach

Applied Composite Materials· Volume 20· Issue 6
Publisher page

Abstract

A significant improvement in the properties of plastic components can be achieved by introducing flexible multiaxial textile grids as reinforcement. This reinforcing concept is based on the layerwise bonding of biaxially or multiaxially oriented, completely stretched filaments of high-performance fibers, e.g. glass or carbon, and thermoplastic components, using modified warp knitting techniques. Such pre-consolidated grid-like textiles are particularly suitable for use in injection moulding, since the grid geometry is very robust with respect to flow pressure and temperature on the one hand and possesses an adjustable spacing to enable a complete filling of the mould cavity on the other hand. The development of pre-consolidated textile grids and their further processing into composites form the basis for providing tailored parts with a large number of additional integrated functions like fibrous sensors or electroconductive fibres. Composites reinforced in that way allow new product groups for promising lightweight structures to be opened up in future. The article describes the manufacturing process of this new composite class and their variability regarding reinforcement and function integration. An experimentally based study of the mechanical properties is performed. For this purpose, quasi-static and highly dynamic tensile tests have been carried out as well as impact penetration experiments. The reinforcing potential of the multiaxial grids is demonstrated by means of evaluating drop tower experiments on automotive components. It has been shown that the load-adapted reinforcement enables a significant local or global improvement of the properties of plastic components depending on industrial requirements.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Mechanical Behavior of Composites · Additive Manufacturing and 3D Printing Technologies · Composite Material Mechanics

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (37)

Show source-provided references
1. Yang, Z., Li, J.P., Zhang, J.X., Lorimer, G.W., Robson, J.: Review on research and development of magnesium alloys. Acta Metall. Sin. 21, 313–328 (2008)10.1016/S1006-7191(08)60054-X ↗
2. Ravi, K.R., Pillai, R.M., Amaranathan, K.R., Pai, B.C., Chakraborty, M.: Fluidity of aluminum alloys and composites: a review. J. Alloys Compd. 456, 201–210 (2008)10.1016/j.jallcom.2007.02.038 ↗
3. Toros, S., Ozturk, F., Kacar, I.: Review of warm forming of aluminum–magnesium alloys. J. Mater. Process. Technol. 207, 1–12 (2008)10.1016/j.jmatprotec.2008.03.057 ↗
4. Sinmazcelik, T., Avcu, E., Bora, M.Ö., Coban, O.: A review: fibre metal laminates, background, bonding types and applied test methods. Mater. Des. 32, 3671–3685 (2011)10.1016/j.matdes.2011.03.011 ↗
5. Ye, H., Yang, X., Hong, H.: Fabrication of metal matrix composites by metal injection molding—a review. J. Mater. Process. Technol. 200, 12–24 (2008)10.1016/j.jmatprotec.2007.10.066 ↗
6. Maison, S., Thibout, C., Garcin, J.L., Payen, H., Sibois, H., Coiffer-Colas, C.: Technical developments in thermoplastic composite fuselages. SAMPE J. 34, 33–43 (1998)
7. Bürkle, E., Sieverding, M., Mitzler, J.: Injection moulding of long-glassfibre-reinforced polypropylene. Kunstst. Plast Eur. 93, 17–19 (2003)
8. Bürkle, E., Mitzler, J.: Injection moulding processes—yesterday, today and tomorrow. Kunstst. Plast Eur. 95, 56–62 (2005)
9. Brüssel, R., Ernst, H., Geiger, O., Henning, F., Krause, W.: LFT—Equipment modifications enable the realisation of new applications. In: 7th International AVK Conference Baden-Baden. 28th and 29th September 2004
10. Schmachtenberg, E., Helpenstein, A.: Direkt ohne handling. LFT im Plastifizier-/Pressverfahren. Plastverarbeiter 54, 88–90 (2003)
11. Beyreuther, R., Brünig, H., Vogel, R.: Preferable filament diameter ratios of hybrid yarn components for optimized longfiber reinforced thermoplastics. Int. Polym. Process. 17, 153–157 (2002)10.3139/217.1681 ↗
12. Bunzel, U., Schneider, K., Lauke, B.: Characterisation of the delamination behaviour of thermoplastic UD-composites made by different hybrid yarn structures. Mater. Sci. Eng. Technol. 28, 465–474 (1997)
13. Krucinska, I., Klata, E., Ankudowicz, W., Dopieraca, H.: Preliminary studies on the manufacturing of hybrid yarns designed for thermoplastic composites. Fibres Text. East. Eur. 8, 61–65 (2000)
14. Krucinska, I., Mikolajczyk, T., Klata, E.: Studies on selecting conditions of manufacturing of composites glass/PA6 from hybrid textile products. Fibres Text. East. Eur. 8, 88–91 (2000)
15. Choi, B.D., Diestel, O., Offermann, P.: CF-PEEK commingling hybrid yarns for textile reinforced light weight rotors—situation and developmental perspective. Chem Fibers Int. 52, 258–260 (2002)
16. Gsteu, M.: Composite yarns for technical textiles based on DREF. Indian Text. J. 111, 93–98 (2001)
17. Offermann, P., Diestel, O., Choi, B.D., Mäder, E., Hübner, T.: Advancement of comingling hybrid yarns for thermoplastic fiber reinforcement composites. Tech. Text. 45, 16–18 (2002)
18. Eng, K., Andersson, C.H.: New ways of composite preforming. Kettenwirk-Praxis 28, 59–62 (1994)
19. Ostgathe, M., Mayer, C., Neitzel, M.: Thermoplastic composites sheets from powder. Kunsts. Plast Eur. 86, 1838–1839 (1997)
20. Mitschang, P., Schledjewski, R.: Processing Technologies: Processing fibre-reinforced plastics. Kunstst. Plast Eur. 93, 189–194 (2003)
21. Hufnagl, E., Böhm, R., Kupfer, R., Engler, T., Cherif, Ch., Hufenbach, W.: Multiaxial textile grids. Kunstst. Int. 4, 54–57 (2011)
22. Cherif, Ch., Franzke, G., Hufnagl, E., Erth, H., Helbig, R., Hufenbach, W., Böhm, R., Kupfer, R.: Textile grids for long fiber reinforced thermoplastic composites made by injection molding. J. Plast. Technol. 4:1–21 (2008)
23. Kendall, D.: Building the future with FRP composites. Reinf. Plast. 5, 26–33 (2007)10.1016/S0034-3617(08)70131-0 ↗
24. Kupfer, R. et al.: TEMAG—Ein neues Verfahren zur Herstellung textilverstärkter Strukturbauteile mit thermoplastischer Matrix. In: VDI Kunststofftechnik. Fachtagung Spritzgießen, Baden-Baden (2008)
25. Kalamkarov, A.L., Hassan, E.M., Georgiades, A.V., Savi, M.A.: Asymptotic homogenization model for 3D grid-reinforced composite structures with generally orthotropic reinforcements. Compos. Struct. 89, 186–196 (2009)10.1016/j.compstruct.2008.07.026 ↗
26. He, J., Ren, M., Sun, S., Huang, Q., Sun, X.: Failure prediction on advanced grid stiffened composite cylinder under axial compression. Compos. Struct. 93, 1939–1946 (2011)10.1016/j.compstruct.2011.02.003 ↗
27. Jadhav, P., Raju, Mantena, P.: Parametric optimization of grid-stiffened composite panels for maximizing their performance under transverse loading. Compos. Struct. 77, 353–363 (2007)10.1016/j.compstruct.2005.07.015 ↗
28. Challagulla, K.S., Georgiades, A.V., Kalamkarov, A.L.: Asymptotic homogenization modeling of smart composite generally orthotropic grid-reinforced shells: part I—theory. Eur. J. Mech. A Solids 29, 530–540 (2010)10.1016/j.euromechsol.2010.03.007 ↗
29. Georgiades, A.V., Challagulla, K.S., Kalamkarov, A.L.: Asymptotic homogenization modeling of smart composite generally orthotropic grid-reinforced shells: part II—applications. Eur. J. Mech. A Solids 29, 541–556 (2010)10.1016/j.euromechsol.2010.03.006 ↗
30. Hassan, E.M., Georgiades, A.V., Savi, M.A., Kalamkarov, A.L.: Analytical and numerical analysis of 3D grid-reinforced orthotropic composite structures. Int. J. Eng. Sci. 49, 589–605 (2011)10.1016/j.ijengsci.2011.02.004 ↗
31. Feuillade, V., Bergeret, A., Quantin, J.C., Crespy, A.: Relationships between the glass fibre sizing composition and the surface quality of sheet moulding compounds (SMC) body panels. Compos. Sci. Technol. 66, 115–127 (2006)10.1016/j.compscitech.2005.05.009 ↗
32. Palmer, J., Savage, L., Ghita, O.R., Evans, K.E.: Sheet moulding compound (SMC) from carbon fibre recyclate. Composites: Part A 41, 1232–1237 (2010)10.1016/j.compositesa.2010.05.005 ↗
33. Bültjer, U.: Produktion von GFK und duroplastischen Formmassen in Europa. In: Proceedings 7, Internationale AVK-TV Tagung. Baden-Baden (2004)
34. Reuther, E.: Kohlefaser SMC für Strukturbauteile. In: Proceedings 7, Internationale AVK-TV Tagung. Baden-Baden (2004)
35. Hausding, J., Widulle, C., Paul, C., Cherif, Ch.: Manufacturing method for symmetric laminates from improved stitch bonded multi-plies. In: Proceedings of ECCM 13 Conference. Stockholm (2008)
36. Hausding, J., Cherif, Ch.: Improvements in the warp knitting process and new patterning techniques for stitch-bonded textiles. J. Text. Inst. 101, 187–196 (2010)10.1080/00405000802370354 ↗
37. Ebert, Ch., Hufenbach, W., Langkamp, A., Gude, M.: Modelling of strain rate dependent deformation behaviour of polypropylene. Polym. Test. 30(2), 183–187 (2011)10.1016/j.polymertesting.2010.11.011 ↗