Patrick Haberkern Patrick Haberkern

Research Area Design – D2:Topology and Shape Optimization

Coupled topology and shape optimization of fiber-reinforced polymer components under multiple manufacturing restrictions

Advisors: Albers (IPEK), Behdinan (UToronto)

Fiber-reinforced polymers play an important role in lightweight design because of their high specific stiffness and strength, among other aspects. DiCoFRP are characterized by anisotropic material properties, which depend on the fiber orientation and distribution. These properties are the result of manufacturing and thus the manufacturing process has a decisive influence on the optimal component design. Since topology and shape optimizations, which are commonly used tools in lightweight design, are usually carried out only isotropically, component designs are often not adapted to the properties of fiber-reinforced polymers.
After the first two generations of GRK 2078 investigated topology and shape optimization, respectively, taking into account the manufacturing of SMC components, the third generation focuses on structural optimization of LFT components. The primary objective of the research is to iteratively couple the LFT-D process with structural optimization, allowing the consideration fiber orientation and distribution in the initial design of DiCoFRTP components. The residual stresses and warpage of the component as a result of the manufacturing process are a major quality issue and will therefore play a central role for the design optimization (Figure). This requires close cooperation with the IRTG partners from the Research Areas Characterization, Design, Simulation and Technology. As far as possible, established software tools will be used with regard to acceptance and applicability in the industry. Therefore, a coupling framework in accordance with the framework from the second generation will be developed.

Figure: Warpage of a component caused by manufacturing process induced residual stresses (scale factor: 10)
Source: Revfi, S., Mikus, M., Behdinan, K., & Albers, A. (2021). On the bead design in LFT structures: The influence of manufacturing-induced residual stresses. Design Science, 7, E5. doi:10.1017/dsj.2021.4