Skip to main content
Springer Nature Link
Log in

Finite element optimisation for rotational moulding with a core to manufacture intrinsic hybrid FRP metal pipes

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Lightweight construction is gaining in importance due to increasing demands for energy efficiency. In drive technology, lightweight shafts can for example be produced in a centrifugal process in which dry, hollow fibre preforms are impregnated with polymer resin and cured under rotation. Furthermore, hybrid FRP-metal lightweight shafts can be produced by intrinsically incorporating additional metal load-introducing elements into the process. Due to the nature of the process, the transition between the materials may be conducted in a form-fitting way. So-called centrifugal cores are used for being able to achieve a higher fibre-volume content or produce polygonal profiles with a form fit. The cores made of a silicone-lead compound expand due to the rotational forces. The resulting pressure leads to a good impregnation of the corner areas. Compared to cylindrical centrifugal cores, polygonal ones have a more complex geometry. Designing with FEM is consequently more appropriate. Therefore, this paper shall portray finite element modelling of a polygonal centrifugal core. The challenge of this endeavour constitutes in developing a centrifugal core, which expansion executes a constant impregnation pressure via the profile onto the impregnated fibre layer. For this purpose, the centrifugal core is modelled as an elastic body in ABAQUS. Subsequently, the centrifugal core’s optimum geometry is derived with an optimisation approach. In conclusion, the calculated centrifugal cores are produced in order to be able to manufacture hybrid shafts.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Hufenbach W, Lenz F, Spitzer S et al (2012) Welle-Nabe-Verbindungen für Leichtbauantriebswellen in Faserverbund-Metall-Mischbauweise. VDI-Fachtagung Welle-Nabe-Verbindungen, Nürtingen, 25th—26th September

  2. Khalid YA, Mutasher SA, Sahari BB et al (2007) Bending fatigue behavior of hybrid aluminum-composite drive shafts. Mater Des 28(1):329–334

    Article  Google Scholar 

  3. Mutasher SA, Sahari BB, Hamouda AM et al (2007) Static and dynamic characteristics of a hybrid aluminium-composite drive shaft. Proc Inst Mech Eng Part L J Mater Des Appl 221(2):63–75

    Google Scholar 

  4. Eksi S, Kapti AO, Genel K (2013) Buckling behavior of fiber reinforced plastic–metal hybrid-composite beam. Mater Des 49:130–138

    Article  Google Scholar 

  5. Fleischer J, Ochs A, Dosch S (2012) The future of lightweight manufacturing—production-related challenges when hybridizing metals and continuous fiber-reinforced plastics. Proceedings of international conference on new developments in sheet metal forming, Stuttgart, 22th—23th May

  6. Lee SW (2007) Torque transmission capability of composite–metal interference fit joints. Compos Struct 78(4):584–595

    Article  Google Scholar 

  7. Ulbricht A, Hufenbach WA, Wohlfahrt D et al (2014) Innovative Leichtbau-Gelenkwellen in hochintegrativer Faserverbundbauweise. Entwicklung und Realisierung eines Demonstrators am Beispiel einer hochbelasteten Gelenkwelle für Schienenfahrzeuge. VDI-Verlag, Düsseldorf, pp 247–251

    Google Scholar 

  8. Barfuss D, Grützner R, Garthaus C et al (2016) Intrinsic manufacture of hollow thermoplastic composite/metal structures. Proceedings 19th ESAFORM, Nantes, 27th—29th April

  9. Fleischer J, Koch S-F, Ruhland P (2016) Rotational molding of fiber reinforced plastics with elastic composite core. Proceedings of international conference on competitive manufacturing. Resource efficiency for global competitiveness. Hrsg. D. Dimitrov and T. Oosthuizen, pp 181–186

  10. Fleischer J, Koch SF, Coutandin S (2015) Manufacturing of polygon fiber reinforced plastic profiles by rotational molding and intrinsic hybridization. Prod Eng Res Devel 9(3):317–328

    Article  Google Scholar 

  11. Koch SF (2017) Fügen von Metall-Faserverbund-Hybridwellen im Schleuderverfahren: Ein Beitrag zur fertigungsgerechten intrinsischen Hybridisierung. Dissertation, Karlsruhe Institute of Technology. Shaker Verlag, ISBN 978-3-8440-5441-5

  12. Diani J, Fayolle B, Gilormini P (2009) A review on the Mullins effect. Eur Polym J 45(3):601–612

    Article  Google Scholar 

  13. Ogden RW, Roxburgh DG (1999) A pseudo-elastic model for the Mullins effect in filled rubber. Proc R Soc Lond A Math Phys Eng Sci 455(1988):2861–2877

    Article  MathSciNet  MATH  Google Scholar 

Download references

Acknowledgements

This paper is based on investigations of the collaborative research program “Schwerpunktprogramm 1712” which is kindly supported by the German Research Foundation (DFG-Deutsche Forschungsgemeinschaft).

Author information

Authors and Affiliations

  1. Karlsruhe Institute of Technology (KIT), wbk Institute of Production Science, Karlsruhe, Germany

    Jonas Nieschlag, Paul Ruhland, Simon Daubner, Simon-Frederik Koch & Jürgen Fleischer

Authors
  1. Jonas Nieschlag
    View author publications

    You can also search for this author inPubMed Google Scholar

  2. Paul Ruhland
    View author publications

    You can also search for this author inPubMed Google Scholar

  3. Simon Daubner
    View author publications

    You can also search for this author inPubMed Google Scholar

  4. Simon-Frederik Koch
    View author publications

    You can also search for this author inPubMed Google Scholar

  5. Jürgen Fleischer
    View author publications

    You can also search for this author inPubMed Google Scholar

Corresponding author

Correspondence to Jonas Nieschlag.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nieschlag, J., Ruhland, P., Daubner, S. et al. Finite element optimisation for rotational moulding with a core to manufacture intrinsic hybrid FRP metal pipes. Prod. Eng. Res. Devel. 12, 239–247 (2018). https://doi.org/10.1007/s11740-017-0788-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-017-0788-6

Keywords