This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Advanced Finite Element Analysis of a Lightweight Nanometal-Polymer Hybrid Component with Experimental Validation, and Its Applications to Vehicle Lightweighting
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 03, 2018 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
The presence of engineering plastics in the automotive, aerospace, and defense industries is rapidly increasing; the lightweight and cost-effective nature of these materials, coupled with improvements to their mechanical performance, is driving the replacement of more traditional materials. However, the stiffness of engineering plastics cannot rival that of their metal counterparts, making metal replacement challenging in cases where stiffness is paramount. Nanometal-polymer hybrids, which are engineering plastics reinforced by a thin high-strength metal coating, provide an innovative solution to this problem. However, implementing this hybrid material into innovative designs remains a challenge, as relatively little information about mechanical behaviour or appropriate modeling techniques for this complex material are available. In this article, an efficient and effective finite element modeling approach for the structural analysis of nanometal-polymer hybrids is presented. The modeling approach is then utilized to assess the performance of a component which is under consideration for metal replacement by nanometal-polymer hybrid material. The geometric and modeling complexity of the component is representative of that found in typical engineering design environments. The results of the finite element model were assessed and validated through direct comparison to experimental data, and demonstrate that the proposed modeling approach provides a level of high degree of accuracy suitable for practical engineering applications.
CitationRyan, L., Wong, J., Pitre, R., Faragalli, M. et al., "Advanced Finite Element Analysis of a Lightweight Nanometal-Polymer Hybrid Component with Experimental Validation, and Its Applications to Vehicle Lightweighting," SAE Technical Paper 2018-01-0152, 2018, https://doi.org/10.4271/2018-01-0152.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
- Vehichle Technologies Office, “Fuel Efficiency and Emissions.”
- Owens, E., Gibbs, J., and Joost, W., “Vehicle Technologies: Materials Technologies,” 2014.
- Davis, S.C., Williams, S.E., Boundy, R.G., and Moore, S., “2016 Vehicle Technologies Market Report,” ISBN 1800553684, 2016, doi:10.2172/1127388.
- Plastics News Research, “In Focus: Plastics in Automotive,” 2016.
- Day, M.R., “Nanometal-polymer hybrid,” Advanced Materials and Processes 166:25-27, 2008.
- Nagarajan, N., Kowpak, T., Tomantschger, K., Gonzalez, F. et al., “Nanometal-Polymer Hybrids: Application of Highstrength Nanocrystalline Metallic Structural Layers on Thermoplastic Articles,” Jahrb. Oberflächentechnik 67:203-217, 2011.
- McCaskie, J.E., “Plating on Plastics,” Metal Finishing 104(5), Nov 2016.
- Olivera, S., Muralidhara, H.B., Venkatesh, K., Gopalakrishna, K., and Vivek, C.S., “Plating on Acrylonitrile-Butadiene-Styrene (ABS) Plastic: A Review,” Journal of Materials Science 51(8):3657-3674, 2016, doi:10.1007/s10853-015-9668-7.
- Saleh, N., Hopkinson, N., Hague, R.J.M., and Wise, S., “Effects of Electroplating on the Mechanical Properties of Stereolithography and Laser Sintered Parts,” Rapid Prototyping Journal 10(1):305-315, 2004.
- Brooks, I., Palumbo, G., Hibbard, G.D., Wang, Z., and Erb, U., “On the Intrinsic Ductility of Electrodeposited Nanocrystalline Metals,” Journal of Materials Science 46(24):7713-7724, 2011, doi:10.1007/s10853-011-5751-x.
- Brooks, I., Lin, P., Palumbo, G., Hibbard, G.D., and Erb, U., “Analysis of Hardness-Tensile Strength Relationships for Electroformed Nanocrystalline Materials,” Materials Science and Engineering A 491(1):412-419, 2008, doi:10.1016/j.msea.2008.02.015.
- Barbero, E.J., “Finite Element Analysis of Composite Materials,” (CRC Press), ISBN 9781420054330, 2008.
- Gaiotti, M. and Rizzo, C.M., “Finite Element Modeling Strategies for Sandwich Composite Laminates under Compressive Loading,” Ocean Engineering 63:44-51, 2013, doi:10.1016/j.oceaneng.2013.01.031.
- Mostafa, A., Shankar, K., and Morozov, E.V., “Behaviour of PU-Foam/Glass-Fibre Composite Sandwich Panels under Flexural Static Load,” Materials and Structures 48(5):1545-1559, 2015, doi:10.1617/s11527-014-0253-3.
- Styles, M., Compston, P., and Kalyanasundaram, S., “Finite Element Modelling of Core Thickness Effects in Aluminium Foam/Composite Sandwich Structures under Flexural Loading,” Composite Structures 86(1):227-232, 2008, doi:10.1016/j.compstruct.2008.03.024.
- Falk, L., “Foam Core Sandwich Panels with Interface Disbonds,” Composite Structures 28:481-490, 1994, doi:10.1016/0263-8223(94)90128-7.
- Gaiotti, M. and Rizzo, C.M., Buckling Behavior of FRP Sandwich Panels Made by Hand Layup and Vacuum Bag Infusion Procedure, “Sustainable Maritime Transportation and Exploitation of Sea Resources,” Taylor & Francis Group, 385-392, 2012.
- Dragoni, E. and Bagaria, W.J., “Numerical and Experimental Validation of a Theoretical Model for Bimaterial Helical Springs,” Journal of Strain Analysis for Engineering Design 48(3):166-176, 2013, doi:10.1177/0309324712469510.
- Dragoni, E. and Bagaria, W.J., “Mechanical Design of Bimaterial Helical Springs with Circular Cross-Section,” Journal of Strain Analysis for Engineering Design 46(4):304-314, 2011, doi:10.1177/0309324711400968.
- Dragoni, E. and Bagaria, W.J., “Formulation of a three-Dimensional Shear-Flexible Bimaterial Beam Element with Constant Curvature,” Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 229(15):2687-2705, 2015, doi:10.1177/0954406214563740.
- Matthews, F.L., “Finite Element Modelling of Composite Materials and Structures,” (CRC Press), ISBN 9781855734227, 2000.
- Osswald, Tim A.; Menges, G., “Material Science of Polymers for Engineers, Third Edition, Knovel,” (Hanser Publishers), ISBN 978-1-56990-514-2, 2012.
- ASTM International, “Standard Test Method for Tensile Properties of Plastics 1,” 17, 2015, doi:10.1520/D0638-14.
- ASTM International, “Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials 1,” 12, 2016, doi:10.1520/D0790-15E02.
- SABIC Innovative Plastics, “CYCOLOY™ Resin MC1300 Datasheet,” 1, https://www.sabic-ip.com/gepapp/eng/weather/weatherhtml?sltRegionList=1002002000&sltPrd=1002003003&sltGrd=1002010406&sltUnit=0&sltModule=DATASHEETS&sltVersion=Internet&sltType=Online, 2016.
- Altair Engineering, “HyperMesh Reference Guide,” 2015.
- Altair Engineering, “OptiStruct Reference Guide,” 2015.