Abstract
Hybrid metal-composite structures offer high potential in lightweight engineering. These hybrid structures bring advantages in strength, stiffness and weight. These hybrid structures are predestined for highly stressed elements such as car body parts. The combination of the different materials leads to a complex process in the design as well as in the manufacturing phase with a multitude of adjustable and interacting parameters. This publication focuses on a deep understanding of the hybrid component to further support the development and digital observed manufacturing process. A stiffness-to-weight improvement for the structure is presented. Potentially relevant parameters are identified from a wide range of geometric variables in each structural element. They were used to set up a parameterized model in SolidWorks and perform a CAD-based parametric FE simulation in ANSYS Workbench. The generated results are used to perform a sensitivity analysis to identify relevant parameters. These key parameters can be readjusted in the design process and provide the basis for a Digital Master in terms of geometry parameters.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Similar content being viewed by others
References
Modler, N., Adam, F., Maaß, J., Kellner, P., Knothe, P., Geuther, M., Irmler, C.: Intrinsic lightweight steel-composite hybrids for structural components. Mater. Sci. Forum 825–826, 401–408 (2015)
Kellner, P.: Zur systematischen Bewertung integrativer Leichtbau-Strukturkonzepte für biegebelastete Crashträger. Dissertation, Technisch Universität Dresden, Dresden (2013)
Haider, D.R., Krahl, M., Gude, M., Kellner, P., Knötschke, D.: Quality-assured process chains for the production of highly loaded lightweight structures in metal-FRP design. Plastics in Automotive Engineering, 14.–15.03.2018, Mannheim (2018)
Gude, M., et al.: Qualitätsgesicherte Prozesskettenverknüpfung zur Herstellung höchstbelastbarer intrinsischer Metall-FKV-Verbunde in 3D-Hybrid-Bauweise. Plattform FOREL Abschlussbericht Q-Pro (2018)
Koshukow, W., Liebsch, A., Kupfer, R., Troschitz, J., Schneider, F., Gude, M.: Entwicklung und Aufbau einer automatisierten Prozesskette für die Herstellung komplexer Kunststoff-Metall-Hybridstrukturen. 27th TECHNOMER, 4.–5.9.2021, Chemnitz (2021)
Haider, D.R., et al.: (2021) Contribution to Digital Linked Development, Manufacturing and Quality Assurance Processes for Metal-Composite Lightweight Structures. In: Dröder, K., Vietor, T. (eds.) Technologies for economic and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer, Berlin (2021)
Schumacher, A.: Optimierung mechanischer Strukturen – Grundlagen und industrielle Anwendungen, 2nd edn. Springer, Berlin (2005)
Seiler, M.S.: Geometric constraints in the context of geometry-based structural optimization of machine components with free-form entities. Dissertation, RWTH Aachen University (2013)
Gräning, L.: Automation of multi-disciplinary analysis processes with ANSA/META and optiSLang. 8th BEFORE REALITY conference, Munich (2019)
Egerland, M., Roos, D., Will, J.: Optimization of a fan shroud by ANSYS/DesignModeler and optiSLang. 25th CADFEM Users’ Meeting 2007, Dresden (2007)
Stark, R., et al.: WiGeP-Positionspapier zum Thema „Digitaler Zwilling“. Zeitschrift für wirtschaftlichen Fabrikbetrieb vol. 115 issue. s1, Hanser, Munich (2020)
Acknowledgements
This research has received funding under the grant number 100339955 (“robust EVP 4.0” project) by the European Regional Development Fund (EFRE) and the German Federal State of Saxony.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2023 The Author(s), under exclusive license to Springer Fachmedien Wiesbaden GmbH, part of Springer Nature
About this paper
Cite this paper
Folprecht, F., Bonn, F., Haider, D.R., Spitzer, S., Gude, M. (2023). Contribution to the Optimization of Metal-Composite Lightweight Structures in Context of Digital Linked Development Processes. In: Dröder, K., Vietor, T. (eds) Future Automotive Production Conference 2022. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Wiesbaden. https://doi.org/10.1007/978-3-658-39928-3_17
Download citation
DOI: https://doi.org/10.1007/978-3-658-39928-3_17
Published:
Publisher Name: Springer Vieweg, Wiesbaden
Print ISBN: 978-3-658-39927-6
Online ISBN: 978-3-658-39928-3
eBook Packages: EngineeringEngineering (R0)