Characteristics of granulates used as core materials in the overmoulding process of hollow profiles

• Published in: Journal of materials processing technology 2020-05, Vol.279, p.116579, Article 116579
• Main Authors: Liebsch, A., Kupfer, R., Hornig, A., Gude, M.
• Format: Article
• Language: English
• Subjects: DEM; Functionalisation of hollow profiles; Granulation; Injection molding; Lightweight; Material properties; Numerical simulation; Overmolding; Overmoulding; Particle; Stiffening; Stiffness
• ISSN: 0924-0136; 1873-4774
• DOI: 10.1016/j.jmatprotec.2019.116579

[Display omitted] The hybridisation of structural components is an effective way to increase its functionality and lightweight potential. By combining different materials and semi-finished products, lightweight and load-adapted components can be achieved. An effective technology is the overmoulding of hollow profiles to realise additional stiffening and fastening elements. For this purpose, a consolidated and dimensionally stable hollow profile is positioned in the injection mould and is overmoulded. It is known, that hollow profiles have to be supported by an internal medium to prevent the structure from collapsing due to the high injection pressure. Previous studies have shown that granulates are well suited as inner support cores. This paper shows the load-bearing behaviour of support granulates consisting of mono-disperse particles. The structural and material properties of the particles are studied experimentally. Subsequently, the load-bearing behaviour of granulates depending on the filling height is investigated and associated with the particle properties. Based on this, numerical studies based on the DEM are carried out to derive the relationship between the particle properties and the load-bearing behaviour of the granular core. Here, a strong dependence between the interparticle-friction as well as the particle stiffness and the deformation of the granulate under compression loading has been observed.