HybCar | Resource-efficient lightweight construction for the automotive industry

Carbon fiber reinforced tapes based on thermoplastic matrix are to be deposited on metallic substrates in accordance with the load path and thus lightweight components are to be manufactured with consideration of resource-saving material use. In doing so, an integrated digital product development should contribute to optimize the flow of materials, the manufacturing process and the costs.

The lightweight construction potential of hybrid mixed construction methods will be demonstrated using the example of a body structure from the automotive sector. This component will be implemented and validated in hybrid construction in the form of a prototype within the framework of the project, whereby the production of the prototype is preceded by digital product development. This includes the further development of automated semi-finished product deposition of thermoplastic tapes on metallic substrates using the fiber placement process, the development and simulation of the forming process for hybrid structures and the development of suitable process monitoring systems. In addition, an individually adapted tape with surface functionalization for ideal adhesion of tape and metal is generated and characterized in the course of detailed material investigations.

The Fraunhofer IGCV focuses on the development of the forming process of the hybrid structure within the framework of the joint project. This includes experimental forming investigations as well as numerical process simulation. Here the Fraunhofer IGCV can draw on know-how from previous projects, such as the aerospace research project GeKo-Therm (FKZ: 20H1311B) or the project MAI re-car (FKZ:03MAI34E) and is therefore predestined to carry out the work package.

Furthermore, the Fraunhofer IGCV takes over the material modeling for the structure simulation with Abaqus. Especially the numerical representation of the boundary layer between thermoplastic tape and metal substrate is part of the work. This is essential for a simulative design of the demonstrator with regard to the necessary stiffness and crash behavior.