Finite Element Analysis of Assembly for Warped Composite Automotive Components
Abstract
One of the most used processes in the automotive industry is the moulding of parts made of thermoplastics filled with glass fibres. This research focused on a specific material: long fibre thermoplastics (LFT). On the one hand, the performance gain, in terms of lightweight and the strength of final components, justifies its wide use. On the other hand, due to the intrinsic characteristics of part manufacturing, warpage is evident and can influence or even compromise subsequent stages of production.
This research has three main objectives: recreate in the most faithfully way, in AbaqusTM environment, the conditions that precede the welding of LFT parts manufactured by moulding; compare gap distances between the assembly fixture and each part, due to their warpage, with the distances provided in the simulation; and finally, allow the prediction of the force acting on the welder's head while the welding is performed.