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An approach for the design of multi-material mechanical components

  • Proc IMechE Part B: J Engineering Manufacture,
  • General

A computational procedure for the calculation of the material parameters involved in the structural design of multimaterial components is presented. The developed scheme can be used in the design process for the full or partial replacement of a metallic part with a metal/fiber–reinforced composite bi-material, aiming at weight savings. Finite element simulations are incorporated into an algorithm that rapidly reduces the design space until a good set of design variables has been reached. The process is controlled by two objective functions (mass and strain energy minimization) and is subjected to several constraints according to the component’s design requirements. Three examples have been adopted to demonstrate the effectiveness of the approach. The results show that the upper limit for weight reduction is constrained by the yield strength of the metal component and therefore its corresponding thickness. Based on the design configuration, weight savings up to 25% could be reached.

Fracture mechanics based assessment of manufacturing defects laying at the edge of CFRP-metal bondlines

  • Production Engineering,
  • General

This study presents a simplified approach for the evaluation of the bond line load capacity of CFRP-metal hybrid structural parts, bearing manufacturing defects. The proposed approach overcomes the need of modeling debonding with the use of advanced non-linear FEM, and relies on the post-processing of the stress and strain fields developed at the free edges of the hybrid material (critical locations in the presence of manufacturing defects), with the use of interfacial fracture mechanics. First, the mathematics, related to the analytical calculation of the bi-material fracture toughness, is presented and applied to a simple CFRP-metal geometry. Corresponding FE simulations are performed and the J-integral is employed for the numerical calculation of the SERR magnitude of different defect sizes. In the following, a simplified calculation of the SERR magnitude that sources from FE results and implemented in geometries modeled by shell finite elements that typically require advanced modeling techniques, is provided for the simulation of the de-bonding process.

Speckle characterization of surface roughness obtained by laser texturing

  • Procedia manufacturing,
  • General

In this work, results obtained from roughness characterization of micro-textured USIBOR steel samples are shown. Laser texturing is used for creating specific periodic microstructures with positive topographies by molten metal displacement technique. Three different methods based on speckle technique (contrast intensity, binary image analysis, spot size measurement) are tested for a contactless inspection and determination of surface roughness. Characterization and calibration relationship are based on the correlation between measured roughness (with conventional methods) and results from speckle techniques.


  • Brussels,
  • General

Workshop organised by AIMEN in the framework of ComMunion Project with the collaboration of Flexhyjoin and Lay2form project

ComMUnion papers

  • General

CIRP procedia papers