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The funding by the German Research Foundation (DFG) is gratefully acknowledged. www.dfg.de

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N. N.

Institut für Produktionstechnik
Kaiserstraße 12
76131 Karlsruhe

Research Area Technology - T4:Postprocessing

Preparation of 3D SMC and LFT composites for joining operations
Advisors: Schulze (wbk), Tutunea-Fatan (UWO)

After the compression molding process, the machining of CoDiCoFRTS parts is necessary in order to meet the required tolerances and to prepare CoDiCoFRTS components for the subsequent joining process. Classical machining processes such as contour milling and borehole drilling are mainly used for this purpose (Figure 1). Both the inhomogeneous characteristics as well as the layer built-up of CoDiCoFRTS can lead to damage in the form of delamination, edge chipping, fiber pullout and fraying during the machining process. Especially at the border between CoFRTS and DiCoFRTS, the machining can cause damage to the workpiece and thus significantly reduce the strength of the whole CoDiCoFRTS part.

The main objective of this PhD project is the development and optimization of new milling and drilling strategies for damage-free machining of CoDiCoFRTS parts under consideration of the fiber cutting angle, tool wear and cutting speed. Additionally, the influence of the clamping system on the resulting workpiece quality will be considered with the aim of minimizing the damage to the workpiece and thus the strength reduction caused by machining processes (Figure 2). The 1st PhD generation will mainly focus on 2D sheets and shells made of CoDiCoFRTS using discontinuous glass fibers and continuous carbon fiber reinforcements.


Figure 1: Contour milling                                   Figure 2: 4-point clamping system