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Life Cycle Assessment of Thermoplastic Hybrid Structures with Hollow Profiles Read chapter Read first chapter

2021 | OriginalPaper | Chapter

Development of a Hybrid Crash-Relevant Car Body Component with Load-Adapted Thickness Properties: Design, Manufacturing and Testing

Authors : Alan A. Camberg, Thomas Tröster, Clemens Latuske

Published in: Technologies for economic and functional lightweight design

Publisher: Springer Berlin Heidelberg

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Abstract

Semi-finished sheet products with load- or forming-adapted properties are classified as tailored blanks. By locally adjusting sheet thickness or material properties, the overall performance of the component can be improved while reducing the weight of the part. State-of-the-art tailored blanks are realized by rolling, welding or tailored heat treatment of monolithic materials and consider a change in properties with respect to the sheet plane. A further weight reduction could be achieved by combining the idea of tailored blanks with a multi-material design approach along the sheet thickness. For this purpose, a top-down material design is proposed to allow a demand-oriented hybrid tailored stacked blank design. Within this contribution an optimization-based top-down design methodology is applied on a crash relevant car body part. Based on benchmark crash simulations of a reference BIW structure, a critical body component is determined. The identified demonstrator component is later subdivided into multiple layers and submitted to an optimization loop in which the developed methodology varies the material parameters for each single layer. The result is a tailored stacked hybrid blank consisting of steel and FRP layers. In order to meet formability restrictions of the novel semi-finished product, the part under investigation is redesigned and compared with the reference BIW structure. Finally, the hybrid component is manufactured and tested on a dynamic crash device. Compared to a monolithic DP800 component, a mass reduction of 22% was achieved.

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previous chapter Experimental Parameter Identification for the Bending Based Preforming of Thermoplastic UD-Tape
next chapter Operationalization of Manufacturing Restrictions for Hybrid Tailored Forming Components
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Metadata
Title
Development of a Hybrid Crash-Relevant Car Body Component with Load-Adapted Thickness Properties: Design, Manufacturing and Testing
Authors
Alan A. Camberg
Thomas Tröster
Clemens Latuske
Copyright Year
2021
Publisher
Springer Berlin Heidelberg
Book
Technologies for economic and functional lightweight design

Print ISBN: 978-3-662-62923-9

Electronic ISBN: 978-3-662-62924-6

Copyright Year: 2021

DOI
https://doi.org/10.1007/978-3-662-62924-6_28

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