Luca Quagliato

Impact resistance of metal skin-carbon fiber reinforced polymer laminate structures for the production of lightweight vehicles body frame

The research presented in this paper deals, in the first part, with the material characterization of an innovative class of material, made of steel skin and sheet molding compound core, the last one realized with vinyl-ester resin and chopped carbon fibers. Utilizing the results of the material characterization, the case of an automotive B-pillar is taken into account in order to test and prove the reliability of the utilization of this innovative typology of material, instead of the standard steel. The steel skin – SMC hybrid laminate structures are realized by means of stamping process under warm forming condition, in order to favorite the curing of the SMC layers. The result presented along the paper will show that the steel skin – SMC material not only have better specific resistance that those of both standard and high strength steel but also better crashworthiness properties, in comparison to the considered steel. Based on the results of the numerical simulations, a useful way thought which to estimate the crash worthiness property is proposed in this paper and the results will show how the B-pillar realized with steel skin – SMC has a higher impact resistance, in comparison the steel one with the same weight and reduced thickness.

Steel skin – SMC laminate structures for lightweight automotive manufacturing

In the present research work an innovative material, made of steel skin and sheet molding compound core, is presented and is aimed to be utilized for the production of automotive body frames. For a precise description of the laminate structure, the material properties of all the components, including the adhesive utilized as an interlayer, have been carried out, along with the simple tension test of the composite material. The result have shown that the proposed laminate structure has a specific yield strength 114% higher than 6061 T6 aluminum, 34% higher than 7075 T6 aluminum, 186% higher than AISI 304 stainless steel (30HRC) and 42% than SK5 high-strength steel (52HRC), showing its reliability and convenience for the realization of automotive components. After calibrating the material properties of the laminate structure, and utilizing as reference the simple tension results of the laminate structure, the derived material properties have been utilized for the simulation of the mechanical behavior of an automotive B-pillar. The results have been compared with those of a standard B-pillar made of steel, showing that the MS-SMC laminate structure manifests load and impact carry capacity comparable with those of high strength steel, while granting, at least, an 11% weight reduction.

Statically determined slip-line field solution for the axial forming force estimation in the radial-axial ring rolling process

In this paper, a statically determined slip-line solution algorithm is proposed for the calculation of the axial forming force in the radial-axial ring rolling process of flat rings. The developed solution is implemented in an Excel spreadsheet for the construction of the slip-line field and the calculation of the pressure factor to be used in the force model. The comparison between analytical solution and authors’ FE simulation allows stating that the developed model supersedes the previous literature ones and proves the reliability of the proposed approach.

Yield strength mapping in the cross section of ERW pipes considering kinematic hardening and residual stress

In the ERW (electric resistance welding) pipe manufacturing, material properties, process conditions and settings strongly influences the mechanical performances of the final product, as well as they can make them to be not uniform and to change from point to point in the pipe. The present research work proposes an integrated numerical model for the study of the whole ERW process, considering roll forming, welding and sizing stations, allowing to infer the influence of the process parameters on the final quality of the pipe, in terms of final shape and residual stress. The developed numerical model has been initially validated comparing the dimensions of the pipe derived from the simulation results with those of industrial production, proving the reliability of the approach. Afterwards, by varying the process parameters in the numerical simulation, namely the roll speed, the sizing ratio and the friction factor, the influence on the residual stress in the pipe, at the end of the process and after each station, is studied and discussed along the paper.