Recently, Carbon Fiber Reinforced Plastic (CFRP) with low density, high strength, stiffness are used widely in number of composite applications such as commercial Automotive industry, aircraft, machinery, and sports equipment. Especially, it is necessary to consider high strength and lightweight mat...
Recently, Carbon Fiber Reinforced Plastic (CFRP) with low density, high strength, stiffness are used widely in number of composite applications such as commercial Automotive industry, aircraft, machinery, and sports equipment. Especially, it is necessary to consider high strength and lightweight materials in automobile for reducing energy consumption and CO2 emissions. In case of the automobile roof panel, high strength and bending stiffness are required for the safety of the driver during the rollover criterion. Generally, CFRP products are manufactured by various process such as injection molding, resin transfer molding(RTM), autoclave, and prepreg compression forming(PCF). PCF is well known for the highest productivity among the manufacturing processes for the CFRP products. The purpose of this study is to design the CFRP roof panel to satisfy required bending stiffness using PCF process. FE-analysis for predicting the bending stiffness of CFRP roof panel manufactured using CFRP is conducted to save production time and cost. To perform FE-analysis, mechanical properties of CFRP specimens fabricated in the orientation of 0°, 45°, 90° were evaluated through tensile test. Using the obtained mechanical properties, 3 point bending analysis for predicting the bending stiffness of CFRP plate was carried out on two cases. Experimental verifications using CFRP plate that has been made under the same conditions were performed by the 3 point bending tests. The structural analysis of the automobile roof panel was conducted using the bending stiffness prediction model validated through the analysis and experiments of the 3 point bending test. As a first step, the automobile roof panel modeled four different thickness such as 1.0. 1.6, 2.0 and 2.6mm have been predicted to satisfy required bending stiffness of 20 N/mm. In order to reinforce bending stiffness of the automobile roof panel, FE-analysis was also used to analyze four different stacking sequence. Also, the design of an heating system and operation conditions of the heating process are very important to PCF process because they both affect the quality of products and production efficiency. Uniform heating improves such defects as porosities, distortion by expansion, and thermal residual stress. Design method for injection molding process is applied to the PCF die to determine the heating channel diameter. And FE-analysis of heat transfer was conducted to determine the number of heating channel. Finally, bending tests of CFRP roof panels manufactured by PCF were carried out to verify FE-analysis considering stacking sequence.
Recently, Carbon Fiber Reinforced Plastic (CFRP) with low density, high strength, stiffness are used widely in number of composite applications such as commercial Automotive industry, aircraft, machinery, and sports equipment. Especially, it is necessary to consider high strength and lightweight materials in automobile for reducing energy consumption and CO2 emissions. In case of the automobile roof panel, high strength and bending stiffness are required for the safety of the driver during the rollover criterion. Generally, CFRP products are manufactured by various process such as injection molding, resin transfer molding(RTM), autoclave, and prepreg compression forming(PCF). PCF is well known for the highest productivity among the manufacturing processes for the CFRP products. The purpose of this study is to design the CFRP roof panel to satisfy required bending stiffness using PCF process. FE-analysis for predicting the bending stiffness of CFRP roof panel manufactured using CFRP is conducted to save production time and cost. To perform FE-analysis, mechanical properties of CFRP specimens fabricated in the orientation of 0°, 45°, 90° were evaluated through tensile test. Using the obtained mechanical properties, 3 point bending analysis for predicting the bending stiffness of CFRP plate was carried out on two cases. Experimental verifications using CFRP plate that has been made under the same conditions were performed by the 3 point bending tests. The structural analysis of the automobile roof panel was conducted using the bending stiffness prediction model validated through the analysis and experiments of the 3 point bending test. As a first step, the automobile roof panel modeled four different thickness such as 1.0. 1.6, 2.0 and 2.6mm have been predicted to satisfy required bending stiffness of 20 N/mm. In order to reinforce bending stiffness of the automobile roof panel, FE-analysis was also used to analyze four different stacking sequence. Also, the design of an heating system and operation conditions of the heating process are very important to PCF process because they both affect the quality of products and production efficiency. Uniform heating improves such defects as porosities, distortion by expansion, and thermal residual stress. Design method for injection molding process is applied to the PCF die to determine the heating channel diameter. And FE-analysis of heat transfer was conducted to determine the number of heating channel. Finally, bending tests of CFRP roof panels manufactured by PCF were carried out to verify FE-analysis considering stacking sequence.
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