Production and modelling of an intrinsic hybrid metal composite for automotive parts

Hybrid parts, which combine low weight with high strength, are moving in the focus of the automotive industry. This contribution deals with the development of an intrinsic hybrid composite made up of a continuous fibre-reinforced plastic, in which a metallic insert is integrated. The connection between these components is realised by a combination of adhesive bonding and a geometrical form fit. To this end, a metallic insert with form fit elements is developed. The form fit elements are generated by out-of-plane deformations induced by a global in-plane load. This in-plane load is applied within the global forming process. Consequently, the intrinsic hybrid composite is produced in an one-step process, which is presented as well. The mechanical properties of the resulting composite are analysed with the help of a finite element simulation of a representative volume element. In this context, inelastic material models at large strains, which are formulated based on directly connected rheological elements, are applied to take account of the mechanical behaviour of the individual components.