A Numerical Simulation for the Hybrid Single Shot (HSS) Process Used to Manufacture Thermoset-Thermoplastic Components

Multi-material design is one of the trending methods for automakers to achieve lightweighting cost-efficiently and meet stringent regulations and fuel efficiency concerns. Motivated by this trend, the hybrid single-shot (HSS) process has been recently introduced to manufacture thermoset-thermoplastic composites in one single integrated operation. Although this integration is beneficial in terms of reducing the cycle time, production cost, and manufacturing limitations associated with such hybrid structures, it increases the process complexity due to the simultaneous filling, forming, curing, and bonding actions occurring during the process. To overcome this complexity and have a better understanding on the interaction of these physical events, a quick yet accurate simulation of the HSS process based on an experimentally calibrated numerical approach is presented here to elucidate the effect of different process settings on the final geometry of the hybrid part. Finally, comparisons were made between the simulation and experimental results using carbon fiber/epoxy prepreg as the thermoset sheets and a Polypropylene compound as the injected thermoplastic with several preheating times, melt temperatures, and injection rates.