On the development of a finite element model to analyze the behavior of hybrid composites considering the manufacturing history

Hybrid parts are strongly moving into the focus for lightweight applications. Unfortunately, the accurate, simulative design, which comprises the accurate prediction of final part geometry, is still a challenging task. In the scope of this paper, an approach to improve the accuracy of appropriate finite element simulations is presented. To this end, the manufacturing history of the hybrid part is considered within the simulation of the part behavior. To create a finite element model of the considered hybrid composite, the intrinsic manufacturing process is modelled first. This includes the modelling of the thermoforming process of a fiber reinforced polymer as well as the sheet metal forming process for the fabrication of form fit elements. Then, the geometry of the hybrid part is deduced from the geometries of the single components. Afterwards, the material properties, including the local fiber volume content as well as the local fiber orientation, are mapped to the finite elements. Consequently, a workflow to create a finite element model which considers manufacturing history is developed and successfully tested.