SEP 2018


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12 CompositesWorld DESIGN & TESTING SEPTEMBER 2018 T O O L I N G Better Quality, Faster Through-put, and Significantly Lower Cost! The Smart Tooling Value Proposition: Smart tooLing ConventionaL tooLing Labor Facilities Consumables totaL CoSt (Composite Part) $ $ $ $ $ $ $ $ $ – $ $ $ $500 – $1,000/lb. $ – $ $ $ $ – $ $ $200 – $400/lb. another level of detail to the already high fidelity of material data from Modules 1 and 2. Given that the anisotropic nature of FRP also applies to strain rate, advanced post-failure testing must employ strain rate-specific test setups, such as drop tower and Split Hopkinson Bar. e key item for Module 3a is the solver-specific result evaluation and material card enrichment. Both material model setup and hardware testing happen in close collaboration to ensure simulation prediction quality. Module 3b – Axial Crush testing is focused on emulating crash structure performance often seen in high-speed vehicle crash testing (Fig. 3, p. 10). Module 2a and 2b are not sufficient to model this behavior. erefore, Module 3 comprises additional drop- tower tests to specifically recognize the energy dissipation capa- bilities of the material through crushing. Although the crush screening (Module 1b) describes the general suitability of the material, Module 3b captures the material behavior at energy levels common to full vehicle crash, and, depending on applica- tion, even realistic levels of strain rate. Standardized material characterization testing program update e development of a comprehensive, flexible, modular material card development program for automotive industry FRP applica- tions, which otherwise would not have been possible without the ABOUT THE AUTHORS Adam Halsband is the NA market manager for Forward Engineering, a global design and engineering firm based in Munich, Germany, which specializes in enabling cost-effective inclusion of fiber-reinforced composites in serial mass- produced automotive structures. From concept development through serial production validation, the company supports automotive industry stakeholders to accelerate the development and commercialization of mixed- material lightweight solutions. Johannes Klug is a senior development engineer with Forward Engineering. He is the lead engineer within the company, and manages the development and implementation of its Modular Material Card Program. In his capacity as one of Forward Engineering's subject matter experts, he interfaces between the design team and partner companies to drive the continuous improvement of the program and the expansion of the Material Card Database. support from industry leaders Zoltek and Hexion, is providing a roadmap for engineers and program managers to guide new product development, overcoming the barriers to adoption of new FRP composites by the automotive industry. e program will continue to grow with the testing of new materials (resins, fibers, cores, adhe- sives/joining solutions, etc.) and manufacturing processes, and this will expand the toolkit available to designers and developers of structural FRP solutions for the automotive industry.

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