The cooperative educational concept of the FAST-LB 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. Mechanical properties of the semi-finished fiber products are to be determined by supervised tests on coupon samples. 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

• Fundamentals of lightweight strategies
• Basics of fiber-reinforced-polymers
• Basics of FEM simulation with anisotropic multi-material systems
• Independent development of suitable component concepts in teams of 4
• Independent development of simulation models for verification and design of own component concepts
• Calculation of anisotropic stiffness parameters from characterization tests
• Manufacturing of fiber-reinforced-polymers
• Mechanical testing

Learning Objectives

Students will be able to name and explain lightweight design strategies. 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. They learn to work independently in teams on an open task, to elaborate the necessary boundary  conditions and parameters and to obtain additional information where necessary.