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Application of carbon reinforced composites and rapid prototyping in low volume automotive production

Durgun, Ismail, Cankaya, Oguzhan, Kus, Abdil and Unver, Ertu (2016) Application of carbon reinforced composites and rapid prototyping in low volume automotive production. Journal of Materials Testing, 58 (10). pp. 870-876. ISSN 0025-5300

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Abstract

In this research, a method was developed for the production of plastic component parts for the use in low volume automotive production. The hollow parts having a complex geometry were produced in blown plastic injection molds. The part production method employed a combination of carbon fiber reinforced composites and rapid prototyping technology. Surface operations were applied on the core model and the effects of the surface quality were researched as a case study. The fused deposition modeling method (FDM) was used to build the core from soluble material. This technique affected the inside surface roughness and quality of the final parts. As these types of components require smooth surfaces for good air flow and low resistance, the surface area of the physical model of the soluble core was too rough to be used directly in the carbon fabric application process and consequently, required preliminary surface treatment in order to improve the surface quality of the manifold part. Specimens were fabricated using different surface treatments in order to determine the smoothest surface quality. The best result was obtained using the acetone-gelcoat post-processing method.

A composite material can be defined as a combination of two or more materials that results in better properties than those of the individual components used alone. In contrast to metallic alloys, each material retains its separate chemical, physical and mechanical properties. The two constituents are the reinforcement and the matrix. The main advantages of composite materials, when compared with bulk materials, are their high strength and stiffness combined with low density allowing for a weight reduction in the finished part [1]. Some properties in combination, such as high specific strength, high specific stiffness or modulus and good dimension stability, give composites advantages not easily obtainable with alloys [2].
Abstract in German:
Anwendung von kohlefaserverstärkten Kompositen und Rapid Prototyping in der Automobilherstellung. In der diesem Beitrag zugrunde liegenden Studie wurde ein Verfahren speziell für die Automobilindustrie für die Produktion von Plastikteilen entwickelt, die in Blas- und Spritzformen in geringen Stückzahlen hergestellt werden und sowohl eine komplexe Geometrie, als auch hohle Teile enthalten. Das Teileproduktionsverfahren wurde in einer Kombination aus kohlefaserverstärkten Kompositen mit Rapid Prototyping untersucht und es wurden die Auswirkungen der Oberflächenbearbeitung des Kernmodells auf die Oberflächenqualität der Teile als Fallstudie untersucht. Um den Kern aus löslichem Material aufzubauen, wurde das so genannte Schmelzschichtungs-Verfahren (Fused Deposition Modeling (FDM)) eingesetzt. Die FDM-Teile beeinflussen die innere Oberflächenrauheit und -qualität der Endteile, zumal die Komponenten dieses Typs eine glatte Oberfläche für einen guten Luftdurchsatz und einen geringen Widerstand benötigen. Das physikalische Modell der löslichen Kernoberfläche erwies sich leider als zu rau, um es direkt im Prozess der Carbontextur anwenden zu können, so dass es zuvor eine Oberflächenbehandlung benötigt. Um die Oberflächenqualität des Krümmers zu verbessern, wurden Proben mit verschiedener Oberflächenbehandlung hergestellt, um die glatteste Oberflächenqualität wählen zu können, und das beste Ergebnis zeigte sich für eine Aceton-Gel-Beschichtungsnachbehandlung des Krümmers.

Item Type: Article
Subjects: T Technology > T Technology (General)
T Technology > TS Manufactures
Schools: School of Art, Design and Architecture
School of Art, Design and Architecture > Innovative design lab
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References:

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Read More: http://www.hanser-elibrary.com/doi/ref/10.3139/120.110926

Depositing User: Ertu Unver
Date Deposited: 27 Oct 2016 10:34
Last Modified: 16 Sep 2017 14:20
URI: http://eprints.hud.ac.uk/id/eprint/29621

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