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Die Erforschung von faserverstärkten Kunststoffen (FVK) mit thermoplastischer Matrix ist aufgrund der Schweißeignung als Verbindungstechnologie, der thermischen Umformbarkeit, der Recyclebarkeit sowie der verkürzten Prozesszeiten im Vergleich zu den vorwiegend eingesetzten faserverstärkten Duroplasten erstrebenswert. Die Wechselwirkung zwischen den physikalischen, mechanischen und geometrischen Parametern erhöht den Komplexitätsgrad des Herstellungsprozesses. Ziel ist daher die Entwicklung einer Imprägniertechnik, die eine Fasertränkung mittels eines Thermoplastschmelzbades ermöglicht.
Basalt fabric composite, with different twill wave reinforcements, i.e. twill 2/2 and twill 1/3, have been studied in this work by means of experimental tests and numerical finite element (FE) simulations. As fabric reinforcements show repeating undulations of warp and fill yarn, simple mixtures law cannot be applied.
As a consequence, the mesoscopic scale, lying between the microscopic and the macroscopic one, has to be taken into account to mechanically characterize a fabric reinforced composite. The aim of this work is to evaluate the stiffness of a fabric reinforced composite in warp and fill direction. In particular a numerical FE
model, assuming elliptical sections and sinusoidal shape of the yarns, has been implemented and experimental tests have been carried out in order to validate the proposed model. Finally, the strength and the failure modes le orientation, have been experimentally investigated.
Purpose:
A prepreg production device in laboratory scale is used to develop the production process of unidirectionally reinforced prepregs.
Design/methodology/approach:
The aim of the prepreg production device is to impregnate different types of reinforcement fibers with an arbitrarily selectable thermoset matrix system that completely satisfies the requirements for autoclave processing. As the prepreg production device is designed and built up modularly every module corresponds one step in the process.
Findings:
To identify the parameters of the production process and investigate its sensitivity on the material quality of both the prepreg as an uncured semi-finished product and the composite as the cured material experimental investigations regarding the resin flow, fiber volume content, mass per unit area and void content are carried out. Overall four material combinations have been investigated, where in each case the selected impregnation temperature and the width of the impregnation gap has been reproducibly varied in selected steps.
Research limitations/implications:
The experimental characterization of the prepregs and of the composite material is carried out according to German standards.
A parametric characterization of a mesomechanic kinematic caused by ondulation in fabric reinforced composites is investigated by analytical and numerical investigations. Due to the definition of plain representative sequences of balanced plain-weave fabric reinforced single layers based on sines the variable geometric parameters are the amplitude and the length of the ondulation. The mesomechanic kinematic can be observed in both the analytic model and the FE-analyses. The analytic model yields hyperbolic correlations due to the strongly simplifying presumptions that neglect elasticity. In contrast the FE-analyses yield linear correlations in much smaller amounts due to the consideration of elastic parts, yet distinctly.
Fiber-reinforced plastic (FRP) tubes are used in many different industries, such as electrical engineering and pipeline construction. The tubes are frequently subjected to bending loads, depending on the application. In order that the dimensioning of the tubes can be ensured, analytical bending models are used to calculate the resulting stresses, strains and displacements in the individual layers of the laminate. This enables the making of a statement about the failure of the fiber-reinforced tube by choosing an appropriate failure criterion. For the use of these bending models, it is necessary to understand the respective underlying theory. The theory provides the basis for the mathematical description of the mechanical properties for a single-layered tube and using the relationships between the stresses and strains that occur in the Cylindrical coordinate system for this calculation step. For this reason, a redefinition of the compliance matrix from the transformation about the winding angle to the Cylindrical coordinate system and a modification of the stress and strain vectors is necessary, because the defined Cartesian coordinate system of the model cannot be used for wounded FRP tubes. The transformation causes an exchange of entries in the compliance matrix, which remain in the correct relationship between the particular stress and strains. This step is not specified and may lead to incorrect results due to the incorrect entry of compliances. The present publication refers to sketch on this issue and represent a simplification of the changeover to the level required by the bending models notation of vectors in the form of a permutation. In addition, a new name for the pre-acquisition of the redefined compliances is given to prevent confusion when entering the material law of a bending model. Finally, the permuted and redefined compliances are proved in an example to determine their accuracy.
Additive Fertigung hat sich in zahlreichen industriellen Anwendungen etabliert und bildet eine wichtige Schlüsseltechnologie. Im Gegensatz zu metallischen Werkstoffen, haben additiv gefertigte Bauteile aus Kunststoffen geringere Festigkeit und Steifigkeit, sodass sich ihre Verwendung als lasttragende Strukturen schwierig gestaltet. Insbesondere der Einsatz von endlosen Verstärkungsfasern kann die mechanischen Eigenschaften additiv gefertigter Strukturen signifikant verbessern und die Fertigung hochbelastbarer Faserverbundstrukturen im 3D-Druckverfahren ermöglichen. Daher gilt es aktuell notwendige Anlagen und Prozessketten für den Fertigungsprozess aber auch Vorgehensweisen für die belastungsoptimierte Auslegung der Faserverläufe innerhalb des Bauteils zu entwickeln, um so das Themengebiet „Endlosfaserverstärkter 3D-Druck“ weiter voranzutreiben. Für mehr räumliche Freiheit bei der Positionierung der Druckbahnen können industrieroboterbasierte Systeme eingesetzt werden, um so das Potenzial gerichteter Bauweise von Faserverbundstrukturen auch im additiven Fertigungsprozess vollumfänglich ausschöpfen zu können. Dabei ermöglicht ihr Einsatz auch eine räumliche Ablage der Faserverstärkung, wobei für die Materialablage ein geeigneter 3D-Druckkopf erforderlich ist. Für die Implementierung der Faserverstärkung ist zudem eine dem Lastfall entsprechende Auslegung des Bauteils sowie die Ermittlung einer sinnvollen Faserpositionierung innerhalb des Bauteils erforderlich, wobei unterschiedliche Variablen aus den Bereichen Material, Struktur und Fertigungsprozess berücksichtigt werden müssen. Im Rahmen des Vortrages werden die Herausforderungen der Technologieentwicklung des endlosfaserverstärkten 3D-Drucks aufgegriffen sowie auf eine belastungsorientierte Faserpositionierung näher eingegangen. Aktuelle Erkenntnisse werden diskutiert sowie eine Entwurfsmethodik für die Prozesspfadgenerierung vorgeschlagen.
Musculoskeletal simulations of lumbar spine loading rely on a geometrical representation of the anatomy. However, this data has an inherent inaccuracy. This study evaluates the influence of defined geometrical parameters on lumbar spine loading utilising five parametrised musculoskeletal lumbar spine models for four different postures. The influence of the dimensions of vertebral body, disc, posterior parts of the vertebrae as well as the curvature of the lumbar spine was studied. Additionally, simulations with combinations of selected parameters were conducted. Changes in L4/L5 resultant joint force were used as outcome variable. Variations of the vertebral body height, disc height, transverse process width and the curvature of the lumbar spine were the most influential.
These parameters can be easily acquired from X-rays and should be used to morph a musculoskeletal lumbar spine model for subject-specific approaches with respect to bone geometry. Furthermore, the model was very sensitive to uncommon configurations and therefore, it is advised that stiffness properties of discs and ligaments should be individualised.
Purpose:
The present work deals with the experimental investigation concerning the energy dissipation capacity of different kinds of reinforcement fibres in monolithic and hybrid layups under high velocity impact loads. The investigated kinds of fibres are carbon, glass and basalt. Design/methodology/approach:
The test panels have been impregnated with thermoset resin. Curing was done by autoclave processing. In order to obtain comparable fibre volume contents of approx. 60 % in the different layups (monolithic and hybrid without and with separating layer), curing cycles adapted to the type of layup have been identified. The resulting fibre volume content of the test panels has been determined both by weighing and experimentally by chemical extraction and calcination. The impact load was applied by an instrumented experimental setup. Thereby both commercially available bullets and bearing balls accelerated with weighted propellant in a sabot have been used as impactors. The measured values are the velocities of the bearing balls as the impactor before and after penetration of the test panels.
Findings:
In both cases the results show the energy dissipation capacity of each single kind of fibre in case of the monolithic layups as well as the enhanced properties of the hybrid stacked layups without and with the separating layer as a core material. Typical failure modes on the impact surface and on the outlet areas are identified.
Research limitations/implications:
The influence of the respective kind of impactors, namely bullets and bearing balls, on the evaluated results is identified. Thereby the bearing balls exhibited a higher degree of reproducibility due to several reasons.
Originality/value:
Fibre reinforced plastics with hybrid stacking sequences can be used as load-bearing structures and at the same time as safety structures for passengers in automotive or aerospace applications. Moreover, with the hybrid stacked composites lightweight concepts can efficiently be realized regarding energy saving issues.
Purpose:
A route to manufacture porous carbon fiber reinforced plastic (CFRP) for study purposes is described.
Design/methodology/approach:
The porous CFRP is characterized using standard techniques such as matrix digestion as well as the more sophisticated method of high resolution Microfocus X-Ray Tomography (μCT). A comparison of the results of those methods is presented. The mass gains of specimens with a wide range of porosity have been measured both in constant humidity and in alternating environments.
Findings:
It could be shown that severe temperature changes can temporarily increase the moisture content of porous CFRP. However, after the return to a constant environment, the moisture content returns back to saturation levels. Furthermore, it could be shown by X-Ray Tomography that even under severe climatic conditions no permanent liquid water condensates inside the pores.
Research limitations/implications:
Using Microfocus Computed Tomography it could be shown that even after nearly a year under hot-wet conditions and more than 150 severe temperature cycles there is no liquid water detectable inside the pores.
Originality/value:
In this paper the effects of severe temperature changes and high humidity on porous CFRP.
Purpose:
A parametric characterization of a mesomechanic kinematic caused by ondulation in fabric reinforced composites is investigated by numerical investigations.
Design/methodology/approach:
Due to the definition of plain representative sequences of balanced plain-weave and twill-weave 2/2 fabric reinforced single layers based on sines the variable geometric parameters are the amplitude and the length of the ondulation.
Findings:
The mesomechanic kinematic can be observed in the FE analyses for both kinds of fabric constructions.
Research limitations/implications:
The FE analyses consider elasticity and contraction due to Poisson effects, respectively, of the model under selected longitudinal strains. Practical implications: The results are evaluated at relevant positions on the centre-line of the ondulated warp-yarn of the plain representative model. A direct and linear coupling in case of the transversal kinematic behaviour, and thereby a corresponding definite reduction of the evaluated longitudinal strains in terms of the difference of the applied and determined longitudinal strains is identified.
Originality/value:
Both characteristic purely kinematic reactions due to geometric constraints directly depend on the introduced degree of ondulation. This non-dimensional parameter relates amplitude and length of one complete ondulation, and thus represents the intensity of the ondulation of the respective fabric construction.
In this paper, the idea of fiber-oriented repair geometries for carbon fiber reinforced plastics (CFRP) is investigated. It considers the differing mechanical properties of unidirectional fiber reinforced material by excluding overlapping regions perpendicular to the fiber direction of the particular layer.
A mechanical and numerical comparison of tensile strength of stepped joints with continuous step lengths per ply and stepped joints with reduced step lengths in plies with fiber orientation differing from load direction is performed.
Finite element simulations show similar shear stresses. Mechanical tests of CFRP laminates with stepped joints show no significant deviation in tensile strength, in spite of a joint length reduction of nearly 40%. This leads to the possibility of a significant reduction of repair area.
This paper describes the results of tensile tests and finite element (FE) calculations with representative volume elements (RVEs) of basalt fibre reinforced plastic with two different types of fabric reinforcements. As fabric reinforcements show repeating ondulations of warp and fill yarn, simple mixtures laws reach their limits. That is the reason why the mesoscopic dimension, lying between the microscopic and the macroscopic dimension, has to be taken into account when a mechanical characterization of fabric reinforced composites is carried out. The aim of this work is to determine the stiffness of a fabric reinforced composite in warp and fill direction with numerical investigations. The simulations are based on FE-calculation with two different RVEs. The tensile tests and the FE-calculations have been carried out for two different types of basalt fabrics, namely twill 2/2 and twill 1/3. The comparison between the experimental data and the results of the FE-calculations are provided in order to support the validity of the proposed model.
Structural mechanic properties of fiber reinforced plastics depend on the single components’ properties, namely matrix and fiber [5]. Simple micromechanic homogenization theories reach a limit when a laminate consists of fabric reinforced layers instead of unidirectional layers. The ondulations of warp and fill yarn caused by the textile semi-finished product are the reason why the mesoscopic scale, which is in between the microscopic and the macroscopic scale, has to be taken into account when mechanically characterizing fabric reinforced composites [3]. In this scale a mesomechanic kinematic can be derived analytically. Especially, when considering free damped vibrations of structures the repeated acting of the kinematic correlation significantly affects the damping behaviour to higher values compared to theoretically predicted damping ratios. The model is investigated using Finite-Element-Analyses and basically validated experimentally.
This paper investigates the damage behavior of thermoset and thermoplastic fiber-reinforced composites. The specimens were subjected to low-velocity impacts (LVI) to produce barely visible impact damages (BVID). To compare the dependency of the matrix system and the laminate lay-up on the impact damage, four test series were set up. Therefore, laminates with an epoxy (EP) and a polyether ether ketone (PEEK) matrix in a quasi-isotropic (QI) [+45/0/-45/90]2s and an orthotropic (OT) fiber lay-up [0/90]4s were manufactured. To eliminate the influence of variant fiber systems, the thermoplastic tape and the thermoset prepreg contain similar carbon fibers (CF). After impact testing with three different impact energies, inner damages were investigated by using ultrasonic analyses. To get a deeper understanding of the interior damage mechanisms, cross sections of the damaged areas were examined via reflected light microscopy. By using these destructive and non-destructive test methods, significant differences in the damage behavior of composites with thermoplastic and thermoset matrix systems were identified for both laminate lay-ups.
Filament wound composite structures are widely used in the field of pressure vessels, tubes, pipelines or rocket cases. The mechanical behavior of these structures is typically different from those of flat laminated structures due to an alternating lay-up sequence, winding tension and manufacturing induced imperfections. However, design and analysis issues require the same engineering data as used for laminated structures in general. It has therefore become necessary to establish an accompanying quality assurance procedure following the production process to identify the material properties of the manufactured tubes especially for the single layer. Consequently, there are three different approaches of determining the elastic moduli and tensile strengths of a filament wound laminate. Either specimens are resected from a curved tube, from a tube with plane areas or standardized flat specimens are manufactured under deviating production conditions. All approaches entail disadvantages, whether in terms of manufacturing or testing parameters including geometry, lay-up sequence, porosity, fiber tension and load direction. This study presents the discrepancies in the determination of mechanical properties of a filament wound glass-fiber-reinforced polymer tube on curved or cylindrical specimens and flat specimens produced to meet the specifications of international standards. In order to obtain material properties not only in longitudinal but also in transverse direction of the tubes, the so-called split-disk tensile test modeled after ASTM Standard D 2290, is used with tube segments.The procedures of specimen production and preparation are described in detail. Material properties such as the fiber volume and void content of the composite specimens are conducted in order to consider quality and production differences. Finally tensile tests are performed and the results are compared and discussed.
Purpose:
A review regarding the acting mechanisms of structural dynamic material damping in fabric reinforced composites is presented. Design/methodology/approach:
Mechanical acting principles identified by different investigations are considered. Aspects of the determination and calculation of structural mechanical material properties of fabric reinforced composites are described. Approaches intending the description and classification of ondulations in fabrics reinforced single layers are demonstrated.
Findings:
The mesomechanic geometry of fabrics is not considered sufficiently by relatively simple homogenization approaches. Yet, it significantly affects its structural dynamic material properties, especially the dynamic ones.
Research limitations/implications:
In each case the different damping mechanisms act coupled and occur at the same time. Therefore a separation procedure is required in any case. Practical implications: Against the background of the comparison and remarks of the presented papers a reasonable further procedure is recommended. Thereby, FE-calculations with a parametrical variation of the mesomechanic geometry in order to identify kinematic correlations due to geometric constraints are suggested.
Originality/value:
The idea of the representation of the geometric conditions in terms of a degree of ondulation is described. Such a non-dimensional specific value representing the intensity of the ondulation would enable the comparability of the results of different kinds of investigations.
The aim of this study is to compare two different standardized testing procedures, tensile testing and Mode-I double cantilever beam (DCB) testing, to evaluate a possible correlation between the dominant failure in glass fibre-reinforced plastics and their according acoustic emissions (AE). AE is processed by using a burst collection of all recorded transient signals and is further analysed with the k-means clustering algorithm. To generate damage related AE, a series of experiments for tensile testing and Mode-I DCB testing is performed on 16-layer glass fibre/epoxy specimens with a cross-ply lay-up for tensile and an unidirectional lay-up for Mode-I DCB testing. Three sensors at tensile testing and one sensor at Mode-I DCB testing gather AE data. The results of clustered burst signals show a good accordance between both testing procedures, with a similar weighted peak frequency (WPF) range in each classified cluster. In total, three different clusters are determined. An assignment of these three clusters to the three dominant damage mechanisms, visually observed by microscopy, is suggested.
Purpose: A route to manufacture porous carbon fiber reinforced plastic (CFRP) for study purposes is described. Design/methodology/approach: The porous CFRP is characterized using standard techniques such as matrix digestion as well as the more sophisticated method of high resolution Microfocus X-Ray Tomography (μCT). A comparison of the results of those methods is presented. The mass gains of specimens with a wide range of porosity have been measured both in constant humidity and in alternating environments. Findings: It could be shown that severe temperature changes can temporarily increase the moisture content of porous CFRP. However, after the return to a constant environment, the moisture content returns back to saturation levels. Furthermore, it could be shown by X-Ray Tomography that even under severe climatic conditions no permanent liquid water condensates inside the pores. Research limitations/implications: Using Microfocus Computed Tomography it could be shown that even after nearly a year under hot-wet conditions and more than 150 severe temperature cycles there is no liquid water detectable inside the pores. Originality/value: In this paper the effects of severe temperature changes and high humidity on porous CFRP.
This paper deals with experimental investigations concerning energy dissipation capacity of different kinds of reinforcement fibres in monolithic and hybrid layups under high-velocity impact loads. The investigated kinds of fibres are carbon, glass and basalt fibres. Therefore test panels, using the same thermoset resin, were built up and cured by autoclave processing. The fibre volume content of the test panels has been determined. Furthermore the influence of a separating layer at selected positions in the hybrid stacked panels was investigated. The results show the influence and the energy dissipation capacity of each single kind of fibre
and the enhanced properties for the hybrid layups by hybrid stacking sequences and the use of a separating core material.
This article presents first results of artificial aging experi-ments by ultraviolet (UV) irradiation on thermoplasticmaterials conducted as an intent of the research project Thermoplastic Composite Structures (TheCoS) in colla-boration of the Ostbayerische Technische Hochschule(OTH) Regensburg and the University of West Bohemia(UWB) in Pilsen as part of a cross-border cooperation. In technical applications, thermoplastic materials are oftenaffected by aging and a related deterioration of the mechanical properties. Therefore, it is necessary to identifythe aging behavior of thermoplastic materials. For this,experiments were performed for three thermoplasticmaterials, namely polypropylene (PP), ultra high mole -cular weight polyethylene (UHMWPE) and high impactstrength polystyrene (HIPS). For these experiments, a UV chamber was constructed according to the internationalstandard EN ISO 4892-3 for simulation of exposurebehind window glass. The results are evaluated by testing the flexural strength and the dynamic mechanicalresponse after a selected period of time under UV lightand then compared to untreated test specimens.
Purpose:
of this paper is experimental investigation of damping properties of unidirectionally and fabric reinforced plastics by the free decay method.
Design/methodology/approach:
For the evaluation of the presumed effect experimental structural dynamic investigations comparing unidirectionally and fabric reinforced plastics are carried out. In detail the free decay behaviour of flat beamlike specimens under fixed-free boundary conditions and relatively constant and reproducible displacement excitation is investigated. Findings: The vibrating structure has been measured by a laser scanning vibrometer PSV 400 from POLYTEC. In both cases evaluation of the results yields enhanced damping properties of the specimens with fabric reinforcement compared to the unidirectionally reinforced specimens. The results justify the presumed acting of a mesomechanic kinematic.
Research limitations/implications:
The results show that in either case the material damping in terms of the logarithmic decrement of the fabric reinforced material is higher than the material damping in of the unidirectionally reinforced material. Additionally, when the fabric reinforced specimens are addressed, in each case the plain weave reinforced specimens exhibited higher values of the material damping as the twill weave 2/2 reinforced ones.
Originality/value:
Ondulations in fabrics as a textile semi-finished product are caused by the alternating crossing of warp and fill yarns. In the mesoscopic scale the acting of a mesomechanic kinematic is presumed to enhance the damping properties under cyclic elastic deformation. For the evaluation of the presumed effect experimental structural dynamic investigations comparing unidirectionally and fabric reinforced plastics are carried out.
Die in Flugvorausrichtung weisenden Bauteile von Luftfahrzeugen sind oftmals durch Einschläge aufgrund von Vogelschlag, Hagel oder aufgewirbelten Kleinteilen gefährdet. Diese Einschläge, sogenannte Impacts, weisen bei faserverstärkten Kunststoffen ein stark krümmungs- und materialabhängiges Verhalten und Schadensausmaß auf. Impact-Schädigungen führen oftmals zu hohen Reparaturkosten, welche durch eine genauere Kenntnis des Schadens verringert werden können. Zur Klassifizierung dieser Schädigungen steht dabei vor allem das auftretende Frequenz signal des Impacts im Fokus der Untersuchungen.
Internationale Forschung zum Biege- und Deformationsverhalten von faserverstärkten Kunststoffrohren
(2019)
Although many composite structures are inconsistently curved, such as the leading edges of aircraft wings, the variety of research in impact engineering is almost limited to the impact performance of plates or cylindrically curved specimens. It is not known whether the findings obtained from standardized tests can be transferred to curved structures or which adaptions are required. Therefore, a deeper understanding of the deformation and damage behavior of inconsistently curved structures is essential to transfer the observed impact behavior of flat specimens to general curved structures and therefore to utilize the full lightweight potential of a load-specific design. An accurate description of the procedure as well as the results of the experimental and numerical study of the low-velocity impact behavior of differently single-curved elliptic specimens is presented. To close the research gap of the impact behavior of geometries with curvatures between the plates and simplified leading edges, novel specimens geometries have been derived from established impact test standards. Glassfiber-reinforced specimens are subjected to an instrumented impact test at constant impact energy. This is numerically investigated by a stacked-layer model, which used cohesive zone modeling to enable the simulation of matrix cracking, fiber fracture and delamination. The resulting projected damage areas, as well as the force and deflection histories, were evaluated and section cuts were examined to discuss the damage morphology, formation and propagation process. Significant effects on maximum deflection, compliance and dynamic behavior on the size and morphology of damage were found.
Forschungsbericht 2013
(2014)
Forschungsbericht 2017
(2017)
High quality semi-finished products with reproducible properties of basaltic fibres are hardly available on the market. In order to examine the properties of basalt fibre reinforced plastics high quality specimens are necessary. The fibre volume content and the porosity of the produced specimen are used as the typical criteria to evaluate the achieved quality of the produced material. The effect of the geometrical properties of the different semi-finished products on the fibre volume contents is relatively small whereas the porosity content is considerably affected.
The effect of process variables such as shear rate and temperature on the viscosity of polypropylene during the processing of thermoplastic based composites was investigated in this study. The melt impregnation is used in the process of continuous glass fibre reinforced thermoplastic composites. To develop a mathematical model for roving impregnation, it's essential to know about the viscous behaviour of the matrix system. Therefore, this paper will discuss rheological models to describe these phenomena, based on the gathered viscosity data from the partner laboratory at the University of West Bohemia in Pilsen.