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Published in:
2021 | OriginalPaper | Chapter
Mesoscale Surface Structures in CFRP-Metal-Hybrid Joints – Aspects of Design and Manufacturing
Authors : Fabian Günther, Markus Stommel
Published in: Technologies for economic and functional lightweight design
Publisher: Springer Berlin Heidelberg
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Abstract
In light weight construction, the concept of multi-material design allows to benefit from the advantageous properties of different materials. Thereby the joining technique for dissimilar materials must always be taken into account. The joining of carbon fibre reinforced polymers and metals is an example where innovative approaches complement or replace the usual joining technology. A special approach is a metal insert overmoulded with a multifunctional polymer, whereby the surface structures improve the intrinsic properties of the compound. These inserts are produced in an injection moulding process.
In this contribution, the forced demouldability of undercuts from mesoscale surface structures is investigated for reinforced and non-reinforced Polyphthalamid (PPA). Simulations predict very high deformations rates for the forced demoulding of the undercuts. In experimental tests, the demouldability of four parts with different angles of inclination (0°, 15°, 30° and 45°) and pins with height of 0.5 mm, 1 mm and 2 mm are examined. Thereby the influence of injection moulding parameters such as melt and mould temperatures is studied by a full factorial Design of Experiments (DoE) analysis. The results show that even undercuts from a 45° inclination angle can be demoulded under certain conditions. The statically evaluation points out that the material reinforcement as well as mould and polymer temperature are the main factors for demouldablitiy of pin undercuts. Finally, an overview of the demoulability of pins is given as a function of the material, pin heights and part inclination angle.