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HyOpt - Optimization-Based Development of Hybrid Materials

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Marcel Triebus at Universität Paderborn
Marcel Triebus
Thomas Tröster
Thomas Tröster
Thomas Tröster
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Abstract

Hybrid materials like fiber-metal laminates (FML) are able to lead to significant weight reduction with load adapted thickness properties. In the interdisciplinary project HyOpt, the optimization-based development of hybrid materials is researched. To ensure that the full lightweight potential of hybrid components is exploited, a holistic top-down approach is considered. Starting with the final geometry and distributed stresses an optimal material distribution can be evaluated and transformed to a semi-finished blank. Nevertheless, the formability of this optimized FML is unknown. Therefore, the formability needs to be investigated and the thickness and surface properties need to be adapted to avoid forming failures. By selecting material proportions, thicknesses and orientation angles, optima can be achieved in terms of lightweight, mechanical properties and forming characteristics.
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CHAIR OF AUTOMOTIVE LIGHTWEIGHT DESIGN
Marcel Triebus, Thomas Tröster
DEVELOPMENT OF HYBRID MATERIALS
HYOPT - OPTIMIZATION-BASED
30.04.2021
9TH NRW NANO CONFERENCE 2021 | APRIL 21-23 | WEB
2
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Introduction
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
[1]
GLARE
Airbus A380
[3]
Tailored
Property
Process
X
Y
Z
Audi A8 D5 (2017)
Aluminum sheet
Aluminum section
Aluminum castings
Magnesium
Conventional steel
Hot formed steel
CFRP
[4]
GFRP
QFRP
Aluminum
CFRP
GLARE
[2]
Aluminum
GFRP Prepreg
Multi-material mix is a common approach nowadays but…
… Lightweight potential of
established materials is
limited
Todays virtual and
technical capabilites allows us
to create tailored parts
3
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
IIHS Small
Overlap
EuroNCAP
ODB
EuroNCAP
Oblique
Pole
IIHS Roof
Crush
US-NCAP
Full Width
How do we find the best material
for our requirements?
[5-7]
A Top-down Approach.
Global Bending
Stiffness
Free-Free
Modal Analysis
Global Torsion
Stiffness
4
Objective structure
A Top-down Approach.
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Sensitivity Component Selection
Strain energy
Crash
Stiffness
[5-7]
Starting with a given objective structure we develop an application tailored material in a
top-down approach
Classify parts into load case relevant groups and rank their impact on the performance
Optimize material for selected components
5
A Top-down Approach.
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Stiffness
Demonstrator Stiffness:
Rear Cross Member
[5-7]
-23 %
-24 %
Metal
FRP
Metal
Fiber-Metal-Laminates can
lead to significant weight
reduction, while keeping the
relevant mechanical
properties equal or better
Material database
of different metals
and reinforced
plastics
[10]
6
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Bending
3-Point-Bending
Torsion
Possible combinations
73= 343
To expensive to consider
all possible layer stack-
up combinations
Variable thickness and
material increases the
optimization problem
exponentially
Multi-objective Optimization.
ℎ 𝒙 = 0
𝑔 𝒙 ≤ 0
7
1
Response Surface Methods.
Simulations
Design Variable 1
Response
(Predicted)
Optimum
2
3
Optimum
Response
Values
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
[8]
8
Load-adapted Material Optimization. 𝒓𝟑𝑷𝑩
𝒓𝑩𝒆𝒏𝒅𝒊𝒏𝒈, 𝒓𝑻𝒐𝒓𝒔𝒊𝒐𝒏
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
Steel
Steel
0° CFRP
90° CFRP
0° CFRP
90°
0°
9
Component selectionSensitivity Optimal hybrid
Objective structure
Load-adapted material optimization
Formability optimization
The HyOpt Approach.
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Load-adapted and formable
semi-finished blank
App
10
Experiments.
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
Simulation.
(all experimal data from @ Paderborn University)
2 mm
Solution through inverse finite element
analysis with numerical one step solver as
used in classical forming simulation tools like
Autoform etc.
11
Formability Optimization.
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
Identify critical forming regions
Adopt fiber orientation to avoid
forming failures
Use fiber placement technology
for semi-finished blanks
[9]
Semi-finished blank
90°
12
Component selectionSensitivity Optimal hybrid
Objective structure
Load-adapted material optimization
Formability optimization
The HyOpt Approach.
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Load-adapted and formable
semi-finished blank
App
18
Marcel Triebus, Thomas Tröster | HyOpt –Optimization-based Development of Hybrid Materials | 9th NRW Nano Conference 2021 | 21-23 April
HYOPT - OPTIMIZATION-BASED
DEVELOPMENT OF HYBRID MATERIALS
Optimization-based Development of Hybrid Materials
Please check our website
www.hyopt.de
for more information!
Marcel Triebus, M. Sc.
Paderborn University
Department of Mechanical Engineering
Chair of Lightweight Automotive Design (LiA)
Telefon: +49 (0) 5251/60-5940
E-Mail: marcel.triebus@uni-paderborn.de
Web: http://www.leichtbau-im-automobil.de
THANK YOU FOR
YOUR ATTENTION!
This Project is funded by the European Union and by the State of North Rhine-Westphalia
20
References
[1] Nguyen, C. D.; Krombolz, C. ; Ucan, H.: Vergleich von Legetechnologien für die automatisierte Glasfaserablage in der Glare-Bauteilfertigung (2018),
www.dlr.de/fa.
[2] www.compositesworld.com/articles/fiber-metal-laminates-in-the-spotlight
[3] Mori, K., Bariani, P. F., Behrens, B.-A., Brosius, A., Bruschi, S., Maeno, T., Merklein, M. u. Yanagimoto, J.: Hot stamping of ultra-high strength steel parts. CIRP
Annals 66 (2017) 2, S. 755–777
[4] www.audi-mediacenter.com/de/audi-a8-50
[5] A. A. Camberg, T. Tröster, Optimization-based material design of tailored stacked hybrids for further improvement in lightweight car body structures 2018,
Proceedings of 3rd Int. Conf. on Hybrid Materials and Structures, Bremen.
[6] Camberg AA, Tröster T, Latuske C. Development of a hybrid crash-relevant car body component with load-adapted thickness properties: Design, manufacturing
and testing. In: Springer; 2021
[7] Camberg AA, Stratmann I, Tröster T. TAILORED STACKED HYBRIDS –AN OPTIMIZATION-BASED APPROACH IN MATERIAL DESIGN FOR FURTHER
IMPROVEMENT IN LIGHTWEIGHT CAR BODY STRUCTURES. In: Technologies for Economical and Functional Lightweight Design. Berlin, Heidelberg; 2019.
[8] LS-Opt Users Manual (2010), www.lsoptsupport.com.
[9] www.tfp-tech.de
[10] Behrens B-A, Hübner S and Neumann A 2014 Forming Sheets of Metal and Fibre-reinforced Plastics to Hybrid Parts in One Deep Drawing Process Procedia
Engineering 81 1608–13.
ResearchGate has not been able to resolve any citations for this publication.
Forming Sheets of Metal and Fibre-reinforced Plastics to Hybrid Parts in One Deep Drawing Process
Article
Full-text available
  • Dec 2014
Each material has its own advantages and disadvantages in terms of its mechanical, chemical and physical properties. Metallic materials are comparatively ductile and easy to process. Fibre reinforced plastics are very stiff and endure high tensile stresses based on their weight. By intelligent combination of these materials into one overall-part light but strong components may be established. However, the conventional production of a separate fibre reinforced plastic (FRP)-component and a metal component and a subsequent joining is time- and labour-intensive and therefore not economical in mass-production. Thus in this paper a new fabrication technology is presented.
View
Development of a Hybrid Crash-Relevant Car Body Component with Load-Adapted Thickness Properties: Design, Manufacturing and Testing
Chapter
  • Mar 2021
Semi-finished sheet products with load- or forming-adapted properties are classified as tailored blanks. By locally adjusting sheet thickness or material properties, the overall performance of the component can be improved while reducing the weight of the part. State-of-the-art tailored blanks are realized by rolling, welding or tailored heat treatment of monolithic materials and consider a change in properties with respect to the sheet plane. A further weight reduction could be achieved by combining the idea of tailored blanks with a multi-material design approach along the sheet thickness. For this purpose, a top-down material design is proposed to allow a demand-oriented hybrid tailored stacked blank design. Within this contribution an optimization-based top-down design methodology is applied on a crash relevant car body part. Based on benchmark crash simulations of a reference BIW structure, a critical body component is determined. The identified demonstrator component is later subdivided into multiple layers and submitted to an optimization loop in which the developed methodology varies the material parameters for each single layer. The result is a tailored stacked hybrid blank consisting of steel and FRP layers. In order to meet formability restrictions of the novel semi-finished product, the part under investigation is redesigned and compared with the reference BIW structure. Finally, the hybrid component is manufactured and tested on a dynamic crash device. Compared to a monolithic DP800 component, a mass reduction of 22 % was achieved.
View
TAILORED STACKED HYBRIDS-AN OPTIMIZATION-BASED APPROACH IN MATERIAL DESIGN FOR FURTHER IMPROVEMENT IN LIGHTWEIGHT CAR BODY STRUCTURES
Chapter
  • Mar 2019
In latest body-in-white (BIW) concepts, engineers take into account a wider range of different materials to pursue a multi-material design approach. However, the lightweight potential of common materials like steel, aluminum or even fiber-reinforcement plastics (FRP) is limited. In keeping with the motto "the best material for the best application", a new approach for a top-down material design is introduced. With the aim to develop an application tailored material, the multi-material concept is adapted for the thickness dimension of the component. Within this contribution a new optimization-based design methodology is applied on a stiffness relevant car body part. Starting with benchmark simulations of a reference BIW structure, a critical car body component is determined by an internal energy based method and a subsequent sensitivity analysis. The identified demonstrator component is later subdivided into multiple layers and submitted to a first optimization loop in which the developed methodology varies the material parameters for each single layer. Once an optimum for the through-thickness properties of the part is found, further optimization loops with concrete material pendants and manufacturing restrictions are carried out. The result is a hybrid laminate part consisting of steel and FRP plies. To achieve a further improvement in body characteristics and lightweight, the investigated part is redesigned by the aim of topology optimization. Finally, the tailored hybrid stacks are validated in BIW simulations and compared with the reference. The optimization-based approach allows a weight reduction up to 25% while maintaining or even improving the BIW properties.
View
Hot stamping of ultra-high strength steel parts
Article
  • Jun 2017
  • CIRP ANN-MANUF TECHN
The demand for new processes to produce high strength parts, under appropriate cost and productivity, has grown with weight reduction and crash safety improvements in automobile design. The hot stamping processes of quenchable steel sheets potentially offer not only small forming load and high formability, but also high strength and no springback by die quenching. This paper aims to provide an overview of the state-of-the-art in such hot stamping processes, including quenchability, formability, heating and cooling approaches and lubrication. The paper also includes a description of the mechanism of formability and quenching, tailoring, analysis of hot stamping processes and applicability.
View
Vergleich von Legetechnologien für die automatisierte Glasfaserablage in der
  • Jan 2018
  • C D Nguyen
  • C Krombolz
  • H Ucan
Nguyen, C. D.; Krombolz, C. ; Ucan, H.: Vergleich von Legetechnologien für die automatisierte Glasfaserablage in der Glare-Bauteilfertigung (2018), www.dlr.de/fa.