Measurement and Analysis of Residual Stresses and Warpage in Fiber Reinforced Plastic and Hybrid Components
Abstract
:1. Introduction
2. Hole Drilling Method
2.1. Principle of the Hole Drilling Method (HDM)
2.2. Calibration Coefficient Calculations
3. Experimental Procedure and Microstructure Characterization
3.1. Sample Preparation
3.2. Microstructure Characterization of the Samples
3.3. Experiment Details Related to Application of the Hole Drilling Method
3.4. Characterization of the Drilled Hole
4. Results and Discussions
4.1. Calculated Calibration Coefficients
4.2. Strain Measurement
4.3. Experimentally Determined Warpage
4.4. Residual Stresses Determined for GFRP
4.5. Reliability of the Residual Stress Measurement in Case of GFRP
4.6. Residual Stresses Comparison of GFRP, CFRP, GFRP/Steel and CFRP/Steel Composites
5. Conclusions
- In the case of the HDM, the zero-depth needs to be carefully determined. A non-exact zero-depth setting strongly biases the resulting residual stresses.
- With a large drilling increment size, the residual stress results suffer from pronounced scatter. It was also found that the resulting residual stresses close to the surface obtained after fast drilling are smaller than after slow drilling. This fact is attributed to the presence of machining induced stresses and local plastic deformation.
- Based on results presented and discussed, optimal drilling parameters were concluded. The reliability of the determination of residual stresses in GFRP using the optimal drilling parameters could be positively validated using mechanical bending tests.
- Obvious warpage induced by residual stresses was observed in the unsymmetrical composites. Only minor warpage was found in symmetrical FRP, the latter most probably being induced by shear forces between the FRP and the tool. The warpage of the CFRP/steel hybrid composite is larger than for the GFRP/steel hybrid composite, due to a higher difference in CTE between CFRP and steel.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Young’s Modulus (GPa) | Poisson’s Ratio | Shear Modulus (GPa) | ||||||||
---|---|---|---|---|---|---|---|---|---|---|
Material | Ex | Ey | Ez | νxy | νxz | νyz | Gxy | Gxz | Gyz | |
CFRP | 126.15 | 7.97 | 7.97 | 0.34 | 0.34 | 0.37 | 7.11 | 7.11 | 2.9 | |
GFRP | 33.98 | 8.78 | 8.78 | 0.33 | 0.33 | 0.37 | 5.23 | 5.23 | 3.21 | |
Steel | 210 | 0.29 |
C11 | 20 μm | 40 μm | 60 μm | C12 | 20 μm | 40 μm | 60 μm |
20 μm | −0.11212567 | 0 | 0 | 20 μm | 0.01578208 | 0 | 0 |
40 μm | −0.13406715 | −0.12199512 | 0 | 40 μm | 0.01814762 | 0.01877189 | 0 |
60 μm | −0.15371703 | −0.14405698 | −0.12675674 | 60 μm | 0.02028894 | 0.02165643 | 0.02136496 |
C13 | 20 μm | 40 μm | 60 μm | C21 | 20 μm | 40 μm | 60 μm |
20 μm | −0.00038726 | 0 | 0 | 20 μm | −0.02488222 | 0 | 0 |
40 μm | −0.00041878 | −0.00040332 | 0 | 40 μm | −0.03055141 | −0.02719248 | 0 |
60 μm | −0.00044319 | −0.00043516 | −0.00041536 | 60 μm | −0.03559672 | −0.0328182 | −0.02850518 |
C22 | 20 μm | 40 μm | 60 μm | C23 | 20 μm | 40 μm | 60 μm |
20 μm | −0.17709626 | 0 | 0 | 20 μm | 0.31686184 | 0 | 0 |
40 μm | −0.19236499 | −0.18393104 | 0 | 40 μm | 0.34161832 | 0.33137709 | 0 |
60 μm | −0.20551438 | −0.19940158 | −0.18879342 | 60 μm | 0.36385533 | 0.35670048 | 0.34154263 |
C31 | 20 μm | 40 μm | 60 μm | C32 | 20 μm | 40 μm | 60 μm |
20 μm | 0.00797854 | 0 | 0 | 20 μm | −0.37465099 | 0 | 0 |
40 μm | 0.00873606 | 0.00931117 | 0 | 40 μm | −0.40524472 | −0.38986754 | 0 |
60 μm | 0.00950009 | 0.0103751 | 0.01049711 | 60 μm | −0.43220678 | −0.42157849 | −0.40169851 |
C33 | 20 μm | 40 μm | 60 μm | ||||
20 μm | 2.6263 × 10−6 | 0 | 0 | ||||
40 μm | 1.1655 × 10−6 | 2.1573 × 10−6 | 0 | ||||
60 μm | −1.0392 × 10−6 | −9.5144 × 10−7 | 1.6632 × 10−7 |
CFRP | GFRP | CFRP/Steel | GFRP/Steel | |
---|---|---|---|---|
C1111 | −0.11212567 | −0.2371058 | −0.09425722 | −0.1457634 |
C1211 | 0.01578208 | 0.0524818 | 0.04266225 | 0.0205167 |
C1311 | −0.00038726 | −0.00037167 | −0.00076925 | −0.0005034 |
C2111 | −0.02488222 | −0.07298181 | −0.01009124 | −0.0323469 |
C2211 | −0.17709626 | −0.21339416 | −0.20073594 | −0.2302251 |
C2311 | 0.31686184 | 0.43392722 | 0.21690341 | 0.41192039 |
C3111 | 0.00797854 | 0.03665156 | 0.03744151 | 0.0103721 |
C3211 | −0.37465099 | −0.45894306 | −0.41178663 | −0.4870463 |
C3311 | 2.6263 × 10−6 | 2.0962 × 10−6 | 1.67 × 10−6 | 3.4142 × 10−6 |
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Wu, T.; Tinkloh, S.; Tröster, T.; Zinn, W.; Niendorf, T. Measurement and Analysis of Residual Stresses and Warpage in Fiber Reinforced Plastic and Hybrid Components. Metals 2021, 11, 335. https://doi.org/10.3390/met11020335
Wu T, Tinkloh S, Tröster T, Zinn W, Niendorf T. Measurement and Analysis of Residual Stresses and Warpage in Fiber Reinforced Plastic and Hybrid Components. Metals. 2021; 11(2):335. https://doi.org/10.3390/met11020335
Chicago/Turabian StyleWu, Tao, Steffen Tinkloh, Thomas Tröster, Wolfgang Zinn, and Thomas Niendorf. 2021. "Measurement and Analysis of Residual Stresses and Warpage in Fiber Reinforced Plastic and Hybrid Components" Metals 11, no. 2: 335. https://doi.org/10.3390/met11020335