October 2018 1milestones in composites
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Smart production technology
for complex fiber composites
ADVANCED ENGINEERING , Birmingham, UK 31 Oct. - 1 Nov., 2018milestones in composites
Automated 3D fiber layup concepts based on
Fiber Patch Placement technologyDr. Neven Majic, Executive Vice President and Co-Founder
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Long production cycles
No effective quality control
High scrap rate
High cost
Need for automation solutions?
Complex composites still manufactured by hand!
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Fiber Patch Placement Additive 3D fiber lay-up technology for complex composites Automated production cells
SAMBA Series
CAE software for part design & production
ARTIST STUDIO
Benefits
up to 50% material and cost savings
Multi-material layup capability
Digitized, automated process chain
100% input material control
www.cevotec.com/en/fpp-technology/
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http://cevotec.com/en/fpp-technology/
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Discontinuous /
patch process
Only the patch process enables high-complexity parts with cost-efficiency and volume capabilities.
Key enabler: the Cevotec patch process
Continuous fiber process
effort / cost
partcomplexity
Processing multiple materials in parallel
100% in-process raw material control
Only Patch Technology enables …
Automated complex direct 3D layup
Customizing local fiber orientations
Continuous fiber
complexity barrier
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The Cevotec patch gripperAdapting to complexity
Key for automated fiber placement on complex surfaces
Controlled fiber deposition
on concave & convex surfaces
Example: Patch Placement onto
a core of a sandwich structure
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Focus industries and applications
Complex
geometries
Tailored
reinforcements
Multi-material
components
Focus industries
Aerospace
Automotive
Medical, industrial
Sports
… Additional
Primary applications
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SAMBA Series
Additive 3D fiber lay-up systems.
Tailored to your requirements.
Modular, scalable components
·Material feeding & cutting e.g. laser, ultrasonic, mechanical
·Quality control cameras incl. image processing computer
·Robot with patch gripper e.g. 4-axis pick & place, 6-axis robot
·Tool manipulator e.g. 6-axis robot, tilting rotator, linear table
SAMBA Pro
flexible series production
SAMBA Scale
high-throughput production
SAMBA Multi
carbon, glass and other fibers
SAMBA Step
entry to patch technology
All systems available in dry fiber and thermoset-prepreg configurations
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SAMBA ProHigh-volume, flexible (batch) series production
Specs
· 10 robot axes for highest degree of product complexity
· Laser cutting for individual patch geometry
· High-res cameras for maximum placing precision
· Fiber throughput ~ 2-3 kg/h
· Fast and easy tool change system
Application areas
· Volume series production of medium to small parts
· Flexible batch series production
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SAMBA ScaleHigh volume, high throughput series production
Specs
· Scaled patch placement system for high fiber throughput
· Robust, durable components for 24/7 production settings
· Integration into industrial composites lines possible
· Fiber throughput ~ 15 kg/h per patch unit
· Fiber throughput > 100 kg/h through combination of units
Application areas
· Volume series production of large to medium-sized parts
· Optimized for continuous, high-throughput production
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SAMBA MultiHigh volume series production for multi-material processing
Application areas
· Volume series production of large to medium-sized parts /
sandwich structures – ideal for aerospace parts
Specs
· Processing different materials (carbon fiber, glass fiber, …)
· 6-axis robot on a linear moving unit
· Varying gripper sizes within the process
· Fiber throughput ~ 15 kg/h
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Continuous process & quality control with a multitude of integrated sensor for key process parameters
Industry 4.0 automation with Fiber Patch Placement
Controlled deposition process
· Temperature
· Pressure
· Compaction time
· Contact time from pick-up to
deposition
Vision control patch position
· Position
· Orientation
· Self-correction process for
precise deposition
Vision control patch
· Width
· Length
· Cutting edge
· Waviness
Real-time production data analysis
and comparison with a database of
previously processed patches
Controlled tape feeding
· Temperature for material storage
· Controlled tape pull-off
· Automatic tape positioning to
centricity
Station for in-process gripper exchange
· Automated detection for contamination
Global parameters:
· Temperature & humidity
in manufacturing cell
· Frequency of patch
deposition
· Cycle time
· Mass throughput
Objective: Replace individual unit tests by continuous process monitoring
Interfaces for integration
into existing process
control landscapes
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SAMBA Step 3DLow-volume, direct 3D production & product development
Specs
· Low-investment entry to patch placement technology
· Flexible degree of automation, here: 9 robot axes
· High precision fiber placement
· Fiber throughput ~ 500 g/h
· Fast and easy tool change system
Application areas
· Flexible, low-volume series production of 3D components
· Prototyping and product development
· Research and development
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Integration of SAMBA in industrial composites linesPatch technology: decrease cost and improve product performance
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Comprehensive CAE software suite for Fiber Patch PlacementEnabling a continuous virtual process chain
CAD – PATCH ARTIST
CAM – MOTION ARTIST
FEA – Artist Studio Plug-in
for commercial FE-Software
Patch-based laminate generation
Offline robot programming
Modeling & Simulation of
mechanical behaviour
(stiffness, strength)
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Production systemsSAMBA Series
The Cevotec portfolio
Your one-stop partner for patch-based production equipment & software
Patch technology services & productsDevelopment, production, spread tow, gripper
CAE softwareARTIST STUDIO
Automation solutions for complex fiber composites
· Direct 3D fiber lay-up systems
· Tailored configurations
· Full automation incl. laminate handling
· CAD-CAM for patch technology
· Export of laminate for FEM
· Perfectly matches SAMBA systems
· Product development, prototyping & series production
· CAE analysis & FEM-based optimization
· Customized fiber spread tow and patch grippers
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We enable manufacturers to produce complex composites in high volume and superior quality.
For a lighter, more sustainable future.
Dr. Neven Majic Executive Vice President
Phone: +49 89 2314 165 31
Email: [email protected]
Summary
·Smart automation based on Fiber Patch
Placement Technology for serial production &
research activities
·Different machine configuration depending
on requirements
·Continuous process & quality control
·Integration-friendly in existing production
lines
·Virtual process chain available
(CAD-CAM-FEM)
Product details:
SAMBA Series & ARTIST STUDIO
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Automated handling of SAMBA fiber laminates
End-to-end automation for complex fiber laminates in series production
·Automated removal from mold
·Innovative tooling concept for first ply release
·Standard gripper equipment for lifting and transport
Increase output and maximize productivity of the SAMBA systems
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SAMBA Step 2.5DLow-volume, 2.5D production & product development
Specs
· Low-investment entry to patch placement technology
· Flexible degree of automation, here: automated layup table
· High precision fiber placement
· Fiber throughput ~ 500 g/h
· Fast and easy tool change system
Application areas
· Flexible, low-volume series production of 2D reinforcements
· Prototyping and product development
· Research and development
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Case Study: Operating box cover with Premium AerotecResults from BMBF-supported project IMPULS
Challenge: Automated layup of operating box cover
Material: Hexcel M21E pregtow (1/2 inch width)
virgin residuals from M-Torres AFP machine
Results: Weight -70%, Cost -75% (to actual version of the part)
Looking forward:
·Continuous, automated process – blueprint for high complexity parts
·New options for manufacturers already using AFP / ATL systems
·Significant material cost savings from re-purposing AFP “left overs”
Volume p.a. [kg] AFP residual material
% FPP repurposing 2,5% 5,0% 7,5% 10,0%
60% 1.350 2.700 4.050 5.400
70% 1.575 3.150 4.725 6.300
80% 1.800 3.600 5.400 7.200
90% 2.025 4.050 6.075 8.100
Value p.a. [€] AFP residual material
% FPP repurposing 2,5% 5,0% 7,5% 10,0%
60% 135.000 € 270.000 € 405.000 € 540.000 €
70% 157.500 € 315.000 € 472.500 € 630.000 €
80% 180.000 € 360.000 € 540.000 € 720.000 €
90% 202.500 € 405.000 € 607.500 € 810.000 €
Material cost savings
Throughput AFP: 25 kg/h
Material: 100 €/kg
Daily production: 18 h
Yearly production: 250 days
OEE: 80%
Note: figures only illustrative.
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ARTIST STUDIO
CAD-CAM software for patch technology
Standalone software platform for a continuous process from CAD to machine data.
Adjusted to match every SAMBA system.
Patch Artist
· Generates high-performance laminates
· Enables complex and curvilinear fiber orientations
· Optimizes patch overlaps and positions
· Works with all standard CAD file formats
· Export of patch laminate for FEM simulation
Motion Artist
· Generates machine data for SAMBA
· Optimizes robot movements
· Simulates the production process, incl. collision detection
· Performs offline programming of SAMBA robots
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Patch laminate architecture for optimized strengthLaminate optimization with comprehensive CAE software suite for Fiber Patch Placement
Fact
Composite materials have a lot of
parameters which can be optimized:
· Fiber direction
· Thickness
· Layer order
· Overlap
FPP: Main performance driver is a load-
path oriented fiber direction and the
patch overlap pattern.
Patch layup enables
high lightweight design potential
>50% better mechanical properties
than conventional laminates!
Fiber overlap
Rel. s
tre
ngth
Overlap pattern type
Strength of
continuous fiber
1 2 3
Fiber direction
1
2
3
20…25% Rel. s
tre
ngth
75% 78%
Only 15° deviation reduces
>80% of fiber utilization.
Optimized patch layup is
increasing the strength*
*tested based on ASTM norm
Beyond application:
The theory, principles and scientific results of patch placement technology
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Natural Fibrous Structures
Human boneTree trunk
Technical Structures
Airport hall Topology
optimized chassis
Curvilinear carbon
fiber orientation
Fibers follow curved paths
→ Transferring the principle to lightweight construction
→ New curvilinear textile technologies
→ Fiber Patch Placement
Direct fiber patch placement on
3D geometry or along 3D load paths
Motivation for Fiber Patch Placement technology
Bionics lightweight design
Leaf
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Fact
Multiaxial non-crimp fabrics such
as quasi-isotropic lay-ups cannot
exploit the full potential of the
material.
Example
Only 15° deviation to a tension-
based load path leads to an
extremely reduced strength
(>80%)
Patch layup supports
optimal lightweight design
Average fiber-to-load deviation is significantly reduced with Fiber Patch Placement
Massive drop in strength of classical laminates
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2.5x stiffness increase with load-optimized patch laminate
High performance lightweight design with Fiber Patch Placement
Source: Cevotec and Technische Universität München
5.23
13.3
5.31
12.35
5.05
13.6
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
quasi isotropic lay-up FPP lay-up
Mass-specific stiffness [kN/(mm∙g)]
+150%
simulation specimen 1 specimen 2 simulation specimen 1 specimen 2150 mm
210 m
m
F F
F F
Optimized patch lay-upQuasi-isotropic lay-up
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Source: O. Meyer, Short fibre preform technology for load path aligned manufacturing of fibre reinforced plastic components, Doctoral thesis, University of Stuttgart, 2008
Mass-specific
maximum strengthF
F
F
F
+120%
Demonstration at an open hole specimen
2.2x strength increase through curvilinear fiber orientation
Biaxial non-crimp fabrics Load path oriented fibers (patch basis)
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MT
MT
Quasi-isotropic lay-up Lay-up with patch layers
4 unidirectional layers
with 2 patch layers8 unidirectional layers
45°
-45°
90°
0°
0°
90°
-45°
45°
MT
MT
FPP
45°
-45°
-45°
45°
FPP
8 unidirectional layers
20% weight reduction
4 unidirectional layers + 2 patch layers
Load-path-oriented reinforcements reduce material, weight and cost
20% weight decrease with patch reinforcements
Cevotec GmbH
Willy-Messerschmitt-Str. 1
82024 Taufkirchen b. München
Phone +49 89 2314 165 0
Fax +49 89 2314 165 99
www.cevotec.com
milestones in composites