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The International Journal of Advanced Manufacturing Technology

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16-01-2024 | ORIGINAL ARTICLE

Investigation of manufacturing process effects on microstructure and fatigue prediction in composite automotive tailgate design

Authors: Joseph Fitoussi, Samia Nouira, Khaled Benfriha, Mohamed Amine Laribi, Achraf Kallel, Robert Tie Bi, Mohammadali Shirinbayan

Published in: The International Journal of Advanced Manufacturing Technology | Issue 9-10/2024

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Abstract

Manufacturing processes significantly influence microstructural variations in short fiber reinforced composites, which affect damage characteristics and fatigue life. Accurate fatigue life prediction is critical, especially when considering the impact of these manufacturing induced microstructural nuances. In this study, we investigate how manufacturing processes shape microstructures and their impact on fatigue life prediction. We present an advanced micromechanical model for predicting fatigue life in tangible structures, considering the microstructure distribution influenced by manufacturing dynamics. Our model links damage from monotonic loading to fatigue life, resulting in a multi-scale fatigue prediction model. This approach builds a database revealing the interaction between Tsai-Wu failure criterion parameters, manufacturing-induced microstructural variations, and target fatigue life. Using these insights, we fine-tune material properties in finite element simulations for precise design optimization. We illustrate our method using an automotive tailgate made from a sheet molding compound. This research highlights the critical role of manufacturing processes in microstructure variation and fatigue life prediction. It offers the potential for significant vehicle weight reduction, energy savings, and reduced emissions in automotive design and promises to be a valuable tool for optimizing manufacturing process parameters.

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Title: Investigation of manufacturing process effects on microstructure and fatigue prediction in composite automotive tailgate design
Authors: Joseph Fitoussi
Samia Nouira
Khaled Benfriha
Mohamed Amine Laribi
Achraf Kallel
Robert Tie Bi
Mohammadali Shirinbayan
Publication date: 16-01-2024
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 9-10/2024
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-024-12988-z

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