Title: Increasing the interlocking effect between metal and FRP by mechanical undercuts

Authors: Klaus Dröder; Michael Brand; Tobias Gebken; Markus Kühn; Markus Böl

Addresses: Institute of Machine Tools and Production Technology, Manufacturing of Hybrid Components, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany ' Institute of Machine Tools and Production Technology, Manufacturing of Hybrid Components, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany ' Institute of Machine Tools and Production Technology, Manufacturing of Hybrid Components, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany ' Institute of Machine Tools and Production Technology, Manufacturing of Hybrid Components, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany ' Institute of Solid Mechanics, Technische Universität Braunschweig, Schleinitzstr. 20, 38106 Braunschweig, Germany

Abstract: One promising approach to achieve automotive lightweight design is the intrinsic combination of metal and fibre reinforced plastics to hybrid parts. These parts can be manufactured by various methods such as injection moulding or thermoforming. However, the joining of the materials and their interface mechanisms remain a limiting factor to using both materials to their full potential. Therefore, it is necessary to develop new technologies to increase the structural integrity of hybrid parts. In this investigation, a load-oriented innovative interlocking concept by specifically designed mechanical undercuts on metal surfaces was developed. In this paper, ultimate loads of interlocking structure patterns were determined, both by a simulation model as well as by experimental investigations. As reference, conventional drill holes were used to create interlocking joints. Furthermore, the paper describes an approach to increase the ultimate load by variation of the structure pattern.

Keywords: hybrid structure; interface modification; lightweight automotive design; mechanical interlocking effect; multi-material system.

DOI: 10.1504/IJAUTOC.2016.084328

International Journal of Automotive Composites, 2016 Vol.2 No.3/4, pp.316 - 329

Received: 02 Sep 2016
Accepted: 04 Feb 2017
Published online: 05 Jun 2017 *

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