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      Application of carbon reinforced composites and rapid prototyping in low volume automotive production Translated title: Anwendung von kohlefaserverstärkten Kompositen und Rapid Prototyping in der Automobilherstellung


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          In this publication, a method was developed for the production of plastic parts for the use in low volume automotive production. The hollow parts having a complex geometry were produced in blown plastic injection molds. The part production method employed a combination of carbon fiber reinforced composites and rapid prototyping technology. Surface operations were applied on the core model and the effects of the surface quality were researched as a case study. The fused deposition modeling method was used to build the core from soluble material. This technique affected the inside surface roughness and quality of the final parts. As these types of components require smooth surfaces for good air flow and low resistance, the surface area of the physical model of the soluble core was unfortunately too rough to be used directly in the carbon fabric application process and consequently, required preliminary surface treatment in order to improve the surface quality of the manifold part. Specimens were fabricated using different surface treatments in order to determine the smoothest surface quality. The best result was obtained using the acetone-gelcoat post-processing method.


          In der diesem Beitrag zugrunde liegenden Studie wurde ein Verfahren speziell für die Automobilindustrie für die Produktion von Plastikteilen entwickelt, die in Blas- und Spritzformen in geringen Stückzahlen hergestellt werden und sowohl eine komplexe Geometrie, als auch hohle Teile enthalten. Das Teileproduktionsverfahren wurde in einer Kombination aus kohlefaserverstärkten Kompositen mit Rapid Prototyping untersucht und es wurden die Auswirkungen der Oberflächenbearbeitung des Kernmodells auf die Oberflächenqualität der Teile als Fallstudie untersucht. Um den Kern aus löslichem Material aufzubauen, wurde das so genannte Schmelzschichtungs-Verfahren (Fused Deposition Modeling (FDM)) eingesetzt. Die FDM-Teile beeinflussen die innere Oberflächenrauheit und -qualität der Endteile, zumal die Komponenten dieses Typs eine glatte Oberfläche für einen guten Luftdurchsatz und einen geringen Widerstand benötigen. Das physikalische Modell der löslichen Kernoberfläche erwies sich leider als zu rau, um es direkt im Prozess der Carbontextur anwenden zu können, so dass es zuvor eine Oberflächenbehandlung benötigt. Um die Oberflächenqualität des Krümmers zu verbessern, wurden Proben mit verschiedener Oberflächenbehandlung hergestellt, um die glatteste Oberflächenqualität wählen zu können, und das beste Ergebnis zeigte sich für eine Aceton-Gel-Beschichtungsnachbehandlung des Krümmers.

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          Most cited references16

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          Critical parameters influencing the quality of prototypes in fused deposition modelling

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            Representation of surface roughness in fused deposition modeling

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              Benchmarking for comparative evaluation of RP systems and processes


                Author and article information

                Materials Testing
                Carl Hanser Verlag
                4 October 2016
                : 58
                : 10
                : 870-876
                1 Bursa, Turkey
                2 Huddersfield, UK
                Author notes
                [* ] Correspondence Address, Dr. İsmail Durgun, TOFAŞ A.Ş., İstanbul Caddesi No: 574, 16369 Osmangazi/Bursa, Turkey, E-mail: ismail.durgun@ 123456tofas.com.tr

                Dr. Ismail Durgun received his BSc degree in Mechanical Engineering from Uludağ University, Bursa, Turkey in 1988. He worked as a research assistant for Uludağ University from 1989 to 1993. He received his MSc degree in Mechanical Engineering from Istanbul Technical University, Turkey in 1991 with his thesis on “Transient Heat Transfer and Cooling Load in Transient Structures” and his PhD degree in Mechanical Engineering from Uludağ University in 1999 with “First and Second Law Analysis of Energy Distribution in a Car Factory and Optimization”. He has been working for TOFAS, Bursa, since 1993, and is the administrator of the Advanced Research Department in R & D. His main research areas are rapid prototyping, low volume sheet metal, plastic and composite part production, manufacturing technologies and automotive design and production.

                Dr. Abdil Kuş received his BSc and MSc on the topic of “Hot Forging Die Design” the Institute of Science and Technology, Gazi University, Ankara, Turkey in 1984 and 1989, respectively. In 1996, he received his PhD from the Department of Mechanical Engineering, Institute of Science and Technology, University of Uludağ, Bursa, Turkey, with the dissertation topic of “Ballistic Impact of Aramid Fabric Composite Panels”. He has been at Uludağ University since 1990 and is currently working as Associate Professor and Head of the Mechanical Engineering Department. His main research areas are computer-aided design and manufacturing technologies, polymer-based composites and machinability of materials.

                Oğuzhan Çankaya is currently writing his PhD thesis on carbon microfiber and carbon nanotubes at the Mechanical Engineering Institute of Science and Technology, Technical University of Sofia, Bulgaria. He has been working at the Vocational School of Technical Sciences, University of Uludağ in Bursa, Turkey, since 2006. He is currently working as a lecturer in the Mechanical Technology Department. His main research areas are machinability of materials and manufacturing technologies as well as carbon fiber polymer composites.

                Dr. Ertu Unver has been Principle Enterprise Fellow (Reader) at University of Huddersfield, School of Art, Design and Architecture, UK since 2014. He worked as a senior lecturer at the same university between 1999 and 2014. He was an industrial design engineer in various UK companies from 1994 till 1999. He also worked at University of Çukurova, Turkey, as a research assistant, lecturer and Associate Professor from 1987 till 1994. He has 10 years industrial and 25 years academic experience in teaching and research on digital technologies, product design, engineering and software development. He is currently the course leader for the MA 3D Digital Design course, and a CAD/CAM manufacturing and technology specialist for product design courses.

                © 2016, Carl Hanser Verlag, München
                Page count
                References: 17, Pages: 7
                Fachbeiträge/Technical Contributions

                Materials technology,Materials characterization,Materials science
                Materials technology, Materials characterization, Materials science


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