Development of Combined Process of Organic Sheet Forming and GMT Compression Forming

Development of a combined one-step process for composite organic sheet forming and GMT sheet (glass fiber mat thermoplastic) compression molding, which can be integrated into the process using conventional stamping techniques and, therefore, does not require an additional injection molding step. Compression molding allows adding a third dimension to a two-dimensional organic sheet. Thus, reinforcements or screw connection points can be made of complex 3D structures with fiber lengths up to 40mm.
  
  While the simulation of two separate processes already exists at a certain level of maturity, the coupling of organic sheet forming and GMT compression moulding in one software tool involves major challenges.
  
   After professional research, a solution method was developed that describes the combined process in a single FE-based forming simulation using LS Dyna. The investigation focuses on the interaction and temperature distribution between the two materials, which largely affects the forming effect of the materials and the adhesion of the materials.