Title: Computing Methodology for SMC Structures Reinforced By Continuous Fiber Reinforcements

Authors: Harald Bachem, Marc Fette, and Eugen Musienko

DOI: 10.33599/nasampe/s.19.1521

Abstract: The demand for fuel efficient aircraft and vehicles led to the development of innovative lightweight constructions and the use of lightweight materials, such as carbon fiber reinforced plastics (CFRP). In the same manner competences in new production technologies have been built up in the aerospace industry. However, current processes for developing and producing composites with an excellent mechanical performance cause high costs and long process cycles in comparison to approved metal processes. Furthermore, the used raw materials, such as carbon fibers and resin, are very expensive. In contrast to these technologies sheet molding compound is characterized by a very high productivity, excellent part reproducibility, cost efficiency and the possibility to realize complex components with integrated functions. The biggest disadvantage of sheet molding compound parts is a low level of stiffness and strength because of a low fiber-volume fraction and a short fiber length. In this context the combination of sheet molding compound (SMC) and pre-impregnated continuous fiber reinforcements in an in-situ compression molding and curing process merges the advantages of both materials to create load-bearing and autoclave-quality parts without an autoclave.

The intention of the present work is the development of a finite element based simulation and optimization method for a new hybrid composite technology for aerospace applications which includes innovative material combinations and an efficient production process in equal measure. The whole development process for the technology is guided efficiently by implementing different numerical optimization methods. Modern simulation methods are applied for validating robust material models, design, dimensioning and calculation of composite or hybrid aircraft components which should be produced with this new technology. This includes a complete structural FEM-analysis, regarding to stresses, strains and rupture of the composite material component. Tools for optimization of topology and laminate will be implemented in order to design load-orientated structures with a minimum of material usage. In addition, the study is based on reference parts from aircraft interior for which functional patterns are designed and manufactured. Prototype testing is performed in order to validate the technology and the virtual optimization as well as simulation methodologies.

References: 1. Fette, M.; Wulfsberg, J.P.; Herrmann, A.; Ziegmann, G.; Lonsdorfer, G.; Stoess, N.: Combination of carbon fibre sheet moulding compound and prepreg compression moulding in aerospace industry. In: Procedia Engineering, 11th International Conference on Technology of Plasticity (ICTP), Nagoya, Japan, 19-24 October 2014, Vol. 81, pp. 1601-1607. 2. Fette, M.; Hentschel, M.; Wulfsberg, J.P.; Herrmann, A.; Stoess, N.: Hybrid sheet molding compound technologies for a new generation of cabin and cargo aircraft components. In: Proceedings of the International Conference SAMPE Long Beach, Long Beach, CA, USA, 2016. 3. Fette, M.; Hentschel, M.; Köhler, F.; Wulfsberg, J.P.; Herrmann, A.: Automated and Cost-Efficient Production of Hybrid Sheet Moulding Compound Aircraft Components. In: Procedia Manufacturing, 16th Machining Innovations Conference for Aerospace Industry (MIC 2016) - New Production Technologies in Aerospace Industry, Hannover, 6 (2016), pp. 132-139, 2016. 4. Bachem, H.; Fette, M.; Pape C.; Wulfsberg, J.P.; Herrmann, A.; Stöß, N.: Simulation and optimization methodology for the development of structures manufactured by a combined sheet moulding compound and prepreg compression moulding process. In: Proceedings of the 18th International Conference on Composite Structures (ICCS), Lisbon, Portugal, 2015, No. 7637. 5. Fette, M.; Hentschel, M.; Guerrero Santafe, J.; Wille, T.; Büttemeyer, H.; Schiebel, P.: New Methods for Computing and Developing Hybrid Sheet Molding Compound Structures for Aviation Industry. In: Procedia CIRP, 1st CIRP Conference on Composite Materials Parts Manufacturing (CIRP CCMPM 2017), Karlsruhe, Germany, Vol. 66 (2017), pp. 45-50, 2017. 6. Altair: RADIOSS 2017 - Reference guide. Vol. 2017. Altair Engineering, Inc., pp. 585-599, 2017.

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1521

Pages: 15

Price: FREE