Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding
Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-02-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/12/5/2296 |
| _version_ | 1797475765367865344 |
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| author | Pascal Mindermann Ralf Müllner Erik Dieringer Christof Ocker René Klink Markus Merkel Götz T. Gresser |
| author_facet | Pascal Mindermann Ralf Müllner Erik Dieringer Christof Ocker René Klink Markus Merkel Götz T. Gresser |
| author_sort | Pascal Mindermann |
| collection | DOAJ |
| description | Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase. |
| first_indexed | 2024-03-09T20:48:29Z |
| format | Article |
| id | doaj.art-455ca1bea46f4fb6a1f52e523aff6b8e |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-09T20:48:29Z |
| publishDate | 2022-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-455ca1bea46f4fb6a1f52e523aff6b8e2023-11-23T22:38:33ZengMDPI AGApplied Sciences2076-34172022-02-01125229610.3390/app12052296Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament WindingPascal Mindermann0Ralf Müllner1Erik Dieringer2Christof Ocker3René Klink4Markus Merkel5Götz T. Gresser6Institute for Textile and Fiber Technologies, University of Stuttgart, Pfaffenwaldring 9, 70569 Stuttgart, GermanyInstitute of Industrial Manufacturing and Management, University of Stuttgart, Allmandring 35, 70569 Stuttgart, GermanyInstitute of Industrial Manufacturing and Management, University of Stuttgart, Allmandring 35, 70569 Stuttgart, GermanyInstitute for Virtual Product Development, Aalen University of Applied Sciences, Beethovenstraße 1, 73430 Aalen, GermanyInstitute for Virtual Product Development, Aalen University of Applied Sciences, Beethovenstraße 1, 73430 Aalen, GermanyInstitute for Virtual Product Development, Aalen University of Applied Sciences, Beethovenstraße 1, 73430 Aalen, GermanyInstitute for Textile and Fiber Technologies, University of Stuttgart, Pfaffenwaldring 9, 70569 Stuttgart, GermanyAdditive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase.https://www.mdpi.com/2076-3417/12/5/2296coreless filament windingmulti-stage windinglaser powder bed fusionfiber-composite/metal–hybrid structuredigital design toolgraph theory |
| spellingShingle | Pascal Mindermann Ralf Müllner Erik Dieringer Christof Ocker René Klink Markus Merkel Götz T. Gresser Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding Applied Sciences coreless filament winding multi-stage winding laser powder bed fusion fiber-composite/metal–hybrid structure digital design tool graph theory |
| title | Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding |
| title_full | Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding |
| title_fullStr | Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding |
| title_full_unstemmed | Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding |
| title_short | Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding |
| title_sort | design of fiber composite metal hybrid structures made by multi stage coreless filament winding |
| topic | coreless filament winding multi-stage winding laser powder bed fusion fiber-composite/metal–hybrid structure digital design tool graph theory |
| url | https://www.mdpi.com/2076-3417/12/5/2296 |
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