Author(s) Holger Seidlitz, Lars Ulke-Winter, Colin Gerstenberger, Lothar Kroll

Affiliation(s)
Institute of Lightweight Structures, Chemnitz University of Technology, Chemnitz, Germany.

ABSTRACT

Reliable line production processes and simulation tools play a central role for the structural integration of thermoplastic composites in advanced lightweight constructions. Provided that material-adapted joining technologies are available, they can be applied in heavy-duty multi-material designs (MMD). A load-adapted approach was implemented into the new fully automatic and fault-tolerant thermo mechanical flow drill joining (FDJ) concept. With this method it is possible to manufacture reproducible high strength FRP/metal-joints within short cycle times and without use of extra joining elements for the first time. The analysis of FDJ joints requires a simplified model of the joint to enable efficient numerical simulations. The present work introduces a strategy in modeling a finite-element based analogous-approach for FDJ-joints with glass fiber reinforced polypropylene and high-strength steel. Combined with a newly developed section-force related failure criterion, it is possible to predict the fundamental failure behavior in multi-axial stress states. The functionality of the holistic approach is illustrated by a demonstrator that represents a part of a car body-in-white structure. The comparison of simulated and experimentally determined failure loads proves the applicability for several combined load cases.

KEYWORDS
Composites, Multi-Material-Design, Hybrid, Joining, Failure Criterion, FDJ Joint

Cite this paper
Seidlitz, H. , Ulke-Winter, L. , Gerstenberger, C. and Kroll, L. (2014) Dimensioning of Punctiform Metal-Composite Joints: A Section-Force Related Failure Criterion. Open Journal of Composite Materials, 4, 157-172. doi: 10.4236/ojcm.2014.43018.

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