Lightweight constructions with fiber-reinforced-polymers - theory and practice


The cooperative educational concept of the FAST-LBT and IAM-WK give students an understanding of theory and practice for lightweight constructing with fiber-reinforced-polymers. Students solve an engineering lightweight task in small groups (max. 4 p.), for example the construction of an optimal bending beam under certain space and weight conditions. Various Materials (fibers, resins, foams, etc.) as well as relevant material data are provided and can be used any arbitrary combination. In a first step, students develop a theoretical solution and verify it simulative. Therefore, an introductory basic lecture teaches the mechanics and simulations techniques of fiber-reinforced-polymers. In a second step the students manufacture specimens based on their theoretical solution at the IAM-WK. The specimens are then tested on bending machines. The students gain knowledge about fiber-reinforced-polymers (materials, manufacturing, manufacturing effects, restrictions, etc.) and structural analysis simulations (modelling, simplifications, assumptions, material models, etc.) as well as material characterization and testing. Building on the basic lecture the knowledge is gained autonomously by solving realistic practice relevant tasks. The main topics are:

  • Basics of Lightweight strategies
  • Basics of fiber-reinforced-polymers
  • Basics of FEM-simulations with anisotropic material systems
  • Simulative part analysis
  • Manufacturing of fiber-reinforced-polymers
  • Mechanical testing

Learning Objectives: Students will be able to name and explain lightweight designstrategies. They are familiar with typical fiber and matrix materials and their function in fiber composite materials. They will be familiar with the operating principle of a sandwich composite with foam core and will be able to describe and justify typical deformation and stress curves. They can name characteristic mechanical parameters and manufacturing processes. For the numerical analysis of FRP components, the students know simple laminate theories, they can set up a finite element model in Abaqus, select suitable finite elements, evaluate the simulation results and derive conclusions for improving the load-bearing effect. Students know the main steps and boundary conditions for manual fabrication and mechanical testing of fiber composite sandwich structures and can apply them in practice.

Language of instructionGerman