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Solving of Thermoplastic-Carbon Bonding Issue Using Numerical Simulations

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Abstract

The aim of this study was to elaborate on the methods of constructing combined components of a car mirror. The components were made of materials with different thermal expansion coefficient. The basis for the research were numerical simulations prepared in Moldex 3D software. The external cover of a mirror would be made of carbon composite based on epoxy resin (hereafter referred to as carbon), and the internal insert would be made of ABS. The adhesive bonding applied did not provide appropriate properties and led to breaks during usage. After carrying out moldflows it was found that the areas of breaks were determined by the places where fronts of flowing material met during the injection. The cause of breaking was diametrically different thermal expansion of both materials. This induced significant stresses in the adhesive layer. Finally, the effective solution was to change the geometry of the mirror insert made of thermoplastic ABS.

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Acknowledgement

The research is financed from financial resources from the statutory subsidy of the Faculty of Mechanical Engineering, Silesian University of Technology in 2021. Authors would like to acknowledge: FX Carbonelements Sp. z o.o., EDS Poland Sp. z o.o., Paweł Paździor Work Project, MICHAEL Teresa Michalik and KUFIETA S.J. companies for sharing materials and providing content and technical-related supervision; special acknowledge for CoreTech System Co., LTD., producer of Moldex3D software and Biuro konstrukcyjne PawForm company for sharing educational license and for help with software.

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Authors and Affiliations

  1. Department of Computational Mechanics and Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, Gliwice, 44-100, Poland

    Paweł Paździor & Mirosław Szczepanik

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  1. Paweł Paździor
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  2. Mirosław Szczepanik
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Correspondence to Mirosław Szczepanik.

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Paździor, P., Szczepanik, M. Solving of Thermoplastic-Carbon Bonding Issue Using Numerical Simulations. Int.J Automot. Technol. 22, 519–527 (2021). https://doi.org/10.1007/s12239-021-0048-9

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  • DOI: https://doi.org/10.1007/s12239-021-0048-9

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