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Asian Workshop on Aircraft Design Education AWADE 2016

Nanjing University of Aeronautics and Astronautics (NUAA), 08-11 October 2016 http://aircraftdesign.nuaa.edu.cn/AWADE2016

A COMPLEX OF LABORATORIES FOR PRACTICAL TRAINING OF STUDENTS IN COMPOSITE TECHNOLOGY

Valentin I. Khaliulin, Elena M. Gershtein

Kazan National Research Technical University named after A.N. Tupolev Aircraft Manufacturing Department

10, Karl Marx St. 420111, Kazan Russia

e-mail: [email protected], web page: http://www.cct-kai.com

Key words: composite technology, educational and scientific complex, laboratory equipment

Abstract. Described is an experience of the establishment and operation of the complex of laboratories for research and students training in composite technology as well as advanced training of industrial employees. Presented are structure and equipment of the complex.

INTRODUCTION

The Aircraft Manufacturing Department of Kazan National Research Technical University named after A.N. Tupolev offers a program in Design and Production of Composite Parts.

During studies, it is critical to develop practical skills in the domain of composite technology. It is well-known that the application of theory in production of a specific part is the best way to master any discipline. Practical work aimed at manufacturing of specific parts, is the strongest stimulus for creative thinking. If a student obtains practical results that exceed existing design and technology, he or she gets enthusiastic about his or her profession. One may assume with confidence that this student will become a good professional.

Obviously, the most efficient education scheme would be the one which includes a final project featuring a practical section based on production of a composite part.

STRUCTURE OF EDUCATION CENTER The structure and equipment of the complex of education laboratories at the Aircraft

Manufacturing Department is based on the following concepts: а) Laboratory equipment should cover the main stages of composite parts design and

production. To some extent, this structure should look like a small-scale R&D enterprise. Due to the specific character of composite technology and the subject being taught, it is reasonable to have the following laboratories:

− Computer design and simulation; − Material science; − Tooling manufacturing − Preforms production − Molding

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− Quality control − Assembly − Coating − Equipment manufacturing and adjustment − A class of well-known design and technological solutions for composite parts and

tooling b) Laboratories should ensure training of students with various levels of previous

education: − Students who have just started becoming familiar with specific subjects using simple

and clear technology examples. − Students who are doing their graduation project and developing innovative structures

and processes. − Industrial employees within an advanced training program. c) The structure and equipment of the laboratories should meet the requirements of state-

of-the art composite enterprise, and the cutting-edge technologies should be at the disposition of the laboratory.

d) Simulation and digital equipment control should be used at a maximum when processesare designed.

It is obvious that equipment and maintenance of such a laboratory complex requires significant funding. That is why the education center is based on a complex of laboratories of the Center of Composite Technology (CCT). Figure 1 illustrates the extensive structure of this research and education center.

A significant part of expenses for equipment maintenance and composite and auxiliary materials purchase are covered by the revenues from R&D under contracts with industrial partners.

Figure 1: Structure of the United Research and Education Center.


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LABORATORIES EQUIPMENT

Design and simulation lab (Figure 2) provides education in the following areas: а) methods of 3D processing, tooling, and equipment development b) writing of mechanical treatment control programs for NC unitsc) writing of control programs for specific processing equipment, such as a cutter, a

TFP machine, a radial braiding machine, etc. d) development of ply book for processing packagee) development of injection scheme for transfer molding processes and simulation of

injection process f) structural analysis – calculation of deflection mode of composite structuresg) simulation to study production processes.The laboratory is equipped with efficient high-end computers. Siemens NX software is used for geometry design. Items b and c are realized in

specific software. Items d and e are performed in FiberSIM and PAM RTM by ESI Group. Structural analysis (e) is done in ANSYS and NASTRAN.

Figure 2: Laboratory of Computer Simulation.

Material science lab targets training in the domain of physics and chemistry of composites (Figure 3). It should have competences to study the properties of composites, generate new composites with given properties, develop and optimize modes of molding, including thermal compression, transfer and other methods of molding.

This lab is comprised of two parts: Chemistry Department, and Physics and Chemistry Department.


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а

b

Figure 3: Material Science Lab: а –Chemistry Department; b – Physics and Chemistry Department.

Chemistry Department has the standard equipment necessary to study polymers.

Physics and Chemistry Department is equipped with the following devices: − Rheometer to study polymers’ rheology − Dynamic Mechanical Analyzer to study viscoelastic behavior of materials (elastic

modulus) depending on various factors, such as temperature and load application frequencies

− Thermal Mechanical Analyzer to study changes in linear dimensions of material

samples under controlled temperature, time, load and sample atmosphere. − Differential Scanning Calorimeter to study physical and chemical processes in

substances in the wide range of operation temperatures − Optical Microscope − Infrared Spectrometer to study chemistry of polymers.

Laboratory of Processing Tooling aims at development of knowledge and skills in methods and means of molding tooling production. This laboratory is equipped with NC units for mechanical treatment of different materials, such as metals, mold plastic, silicone, etc., and control and measurement equipment (Figure 4).


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Figure 4: Laboratory of Processing Tooling Production.

Laboratory of preforms and pre-laminates production reflects the wide range of state-of-the-art methods for semi-finished net-shape parts production from dry materials and prepregs.

To illustrate the widely known layup preform production, a Zünd cutter and 3D laser projector are used. Layup is performed in a ‘clean zone’ with ISO grade 7, 8.

Innovative methods of preforms production are presented with the following equipment:

а) Tailored fiber placement machine (Figure 5) [1], [2]

b) Radial braiding complex based on HERZOG braiding machine (Figure 6)

c) Tufting and blindstitching complex for preforms manufacturing (Figure 7)


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Figure 5: Tailored Fiber Placement machine (TFP).

Figure 6: Radial Braiding Complex.


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Figure 7: Tufting and Blindstitching Complex.

Laboratory of Molding consists of three departments. In the first department, thermal compression methods are studied (Figure 8). The

following equipment is used: small autoclave (Figure 8, а), hydraulic press (Figure 8, b), pneumatic press (Figure 8, c), vacuum press (Figure 8, d). In the second department, transfer molding is studied, including RTM (Resin Transfer Molding), Light RTM, RFI and infusion. Figure 9 shows two sets of equipment for RTM. In the third department, alternative molding processes are studied, in particular, studies involving a machine for ultra-violet curing. (Figure 10).

а b Figure 8: Equipment for Thermal Compression Molding: а – Autoclave; b – Hydraulic Press;

c – Pneumatic Press; d – Vacuum Press.


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c d

Figure 8 (cont’d): Equipment for Thermal Compression Molding: а – Autoclave; b – Hydraulic Press; c – Pneumatic Press; d – Vacuum Press.

Figure 9: Complex for RTM.


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Figure 10: Machine for Ultra-Violet Curing.

Analytic equipment developed and produced by Inasco is used to study transfer molding and real-time monitoring of composite parts production based on material states. (Figure 11).

Figure 11: Machine to Study Resin Flow in a Preform.

Quality control laboratory includes four departments: parts and tooling geometry control, material quality control, static testing and impact testing.

To control parts and tooling geometry, an arm-type control and measurement machine is necessary. It may work either in contact or in scanner mode (Figure 12).

Material quality control is performed with an Omniscan MX2 ultrasound inspection machine (Figure 13).


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Figure 12: Control and Measurement Machine.

Figure 13: Non-Destructive Inspection of Composites.

To study static testing methods, a universal electrical mechanical machine, climate chamber and a set of testing tooling are used (Figure 14).


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Figure 14: Tooling and Machine for Static Strength Testing.

Figure 15 demonstrates equipment that is used to study impact resistance and durability. The set includes a vertical impact machine, a pendulum machine and testing tooling.

Figure 15: Equipment for Impact Testing.

Assembly and joining lab (Figure 16) is arranged to study methods of thin-walled composite parts location, methods of reconciliation of dimensions and accuracy ensuring, as well as creation of mechanical and adhesive joints. This laboratory is equipped with stocks for location and assembly of two- and three-dimensional units. These units contain truss and shell composite elements. Specific tooling and instruments are used to study assembly methods.


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Figure 16: Assembly Lab.

Laboratory of equipment production and adjustment (Figure 17) provides the basis for implementation of creative initiative of students and research assistants.

Under supervision of faculty staff, scientific and technical ideas that are born while working on graduate projects and theses find their way here [3].

Figure 17: Laboratory of Innovative Equipment.

SUMMARY

1. The aforementioned complex of laboratories:− provides students with practical skills in composite parts production − gets students familiar with processing equipment, and operating as well as

programming of this equipment − provides conditions for scientific and technical creativity.


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2. This complex of laboratories unites the main industrial processing methods. At thesame time, it does not cover a range of technologies, such as winding, pultrusion, spraying and methods of thermoplastic composites processing. Thus, a cooperation of universities that are mutually complimentary when it comes to equipment and processes seems to be reasonable. This lack may be compensated for by cooperation implemented within a network education system or training in an industrial enterprise that has the necessary equipment.

3. Operation of the complex is possible only when it is combined with R&D centerthat has revenues to cover the major expenses of training.

4. Key element for fully-fledged operation of training labs is academic literature thatincludes books, manuals for practical training sessions, project tasks, etc.

5. Methodology of the center should include a set of topics for prospective graduateprojects. These topics should meet the requirements of a composite technology long-term development strategy.

REFERENCES [1] Khaliulin, V.I., Khilov, P.A., Toroptsova, D.M. Prospects of Applying the Tailored

Fiber Placement (TFP) Technology for Manufacture of Composite Aircraft Parts. Russian Aeronautics, vol. 58, No. 4, 2015, pp. 495 – 500.

[2] Mattheij, P., Gliesche, K., Feltin, D. Tailored Fiber Placement-Mechanical Properties and Applications. Journal of Reinforced Plastics and Composites, vol. 17, no. 9, 1998, pp. 774-786.

[3] Khaliulin, V.I., Razdaibedin, A.A. Determination of Processing Parameters for the Folded Core with Enveloping Curvilinear Surface. Russian Aeronautics, vol. 58, No. 1, 2015, pp. 88-96.

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