Visualization Framework for Assisting Interface Optimization of Hybrid Component Design

Abstract

Reliable component design is one of structural mechanics' main objectives. Especially for lightweight constructions, hybrid parts made of a multi-material combination are used. The design process for these parts often becomes very challenging. The critical section of such hybrid parts is usually the interface layer that often builds the weakest zone. In this paper, we study a hybrid part made of metal and carbon fiber-reinforced composite, where the metal insert is coated by a thermoplastic to decrease the jump in stiffness between the two primary structural materials. To prevent stress peaks in small volumes of the part , mechanical engineers aim to design functional elements at the thermoplastic interface, to homogenize the stress distribution. The placement of such load transmitting functional elements at the thermoplastics interface has a crucial impact on the overall stability and mechanical performance of the design. Resulting from this, mechanical engineers acquire large amounts of simulations outputting multi-field datasets, to examine the impact of differently designed load transmitting elements, their number, and positioning in the interface between metal and composite. In order to assist mechanical engineers in deeper exploration of the often numerous set of simulations, a framework based on visual analytics techniques was developed in close collaboration with engineers. To match their needs, a requirement analysis was performed, and visualizations were discussed steadily. We show how the presented framework helps engineers gaining novel insights to optimize the hybrid component based on the selected load transmitting elements.