hollow hp-rtm carbon fiber parts -...
TRANSCRIPT
Hollow HP-RTM Carbon Fiber PartsTobias JansenSales Manager Composites & AdvancedApplications, Hennecke GmbH
Tobias Jansen, Sales Manager
Composites & Advanced Applications
Hennecke GmbH
Hollow HP-RTM CarbonFiber Parts
Slide 3
Hennecke GmbH, Sankt Augustin(Germany)
1945 Founded by Karl Hennecke in SanktAugustin
1955 Development of the first high-pressuremetering machine
2011 Presentation of HP-RTM technologyand an accompanying processing system forthe production of fibre-reinforced structuralcomponents
Number of employees of the HenneckeGroup: ca. 500 (January 2016)
Ownership: 100 percent Capvis Equity IVL.P.
Worldwide presence through local agenciesin over 100 countries
Slide 4
Founded in 1968
Comprehensive sales and after-salesportfolio with expert consulting, engineeringand retrofit services
Experienced specialists in sales, projectmanagement, design and service
Hennecke Inc. TECHCENTER for livedemonstration, courses, customer demosand trials
Employees: 44
Hennecke Inc., Pittsburgh (USA)
Slide 5
Agenda
Explanation of the CAVUS technology
Project „License plate holder“
Sand core process
Braiding process
Introduction of HP-RTM process
HP-RTM production cell
HP-RTM raw material
Facts of process
Future potentials
Slide 6
THE CAVUS TECHNOLOGY by
CAVUS – currently a unique process of itskind, innovated by KTM Technologies
Technology for high volume production ofcomplex, structural and hollow CFRP partsin short cycle times
Combination of sustainable, water solublecore material with high volume productionprocesses such as automated preformingand HP-RTM – with the efficient usage ofmaterials and resources
Achievements: high level of automatization,short cycle times, efficient usage of thematerials, cost competitive, eco- andresource-friendly
Slide 7
1. Sand core with binder2. Braiding
3. HP-RTM Injection of aPU Resin
5. Finished hollow part
4. Washing out of the sandcore
THE CAVUS TECHNOLOGY by
Slide 8
Project Definition R.A.C.E.
Partnership project between
o OEM
o Material supplier
o Machine supplier
o University
Design, simulation, testing and productionmachinery for hollow composite parts.Suitable for mass production!
Slide 9
Project „License Plate Holder“
Design specifications:
Lightweight hollow part
New and modern design
Wall thickness ~3mm
Demoldable
Volume ~1l
Slide 10
Simulation and Design
Simulation of the whole manufacturing process
o Braiding process simulation
• Prediction of fibre architecture
• Consideration of real kinematics, material propertiesand friction behaviour
o Mapping of fibre architecture to infiltration model
o Infiltration simulation
• Evaluate the right position of injection and thevacuum valve
• Prediction of the material flow in order to fibreorientation, to core design and to the raw material
Various iterations between design freeze andsimulation process, to define the rightgeometries
Slide 11
The sand core process
New developed core material
o Water as solvent
o Nontoxic core material
o Pressure ressistant up to 200 bars
o Core components separate themselves
o Up to 98% of the core material can be reused
Slide 12
Braiding process
o Fully automatedproduction process
o Load optimized fibreorientation
o Automatic robot pathgeneration based onbraiding simulation
Slide 13
High Pressure Resin Transfer Molding Process (HP-RTM)
The HP-RTM technology allows producersto fill molds with high content of fibrewithin seconds with a thermoset resin likeEpoxy or Polyurethane
Therefore raw materials can have a highreactivity for snap curing effects
Vacuum assists during evacuation of themold and during shot to achieve the rightflow path
The HP-RTM technology allows highlyautomated processes and short cycle timesfor parts with complex 3-D geometries
HP-RTM technology is suitable for massproduction.
Slide 14
STREAMLINE for HP-RTM processing
Modular design
Polyurethane
Epoxy Resin
Caprolactam / PA6
Slide 15
HP-RTM composite resins
Polyurethane or epoxy based systems
Standard Tg and high Tg grades
Tunable reaction kick-off
Low viscosity until Snap Cure
Curing time of less than one minutepossible
High mechanical performance:toughness & ductility
Internal release agent available
Com
plex
vis
cosi
ty[P
as]
time
Conventional resintunable
Com
plex
vis
cosi
ty[P
as]
time
Conventional resintunable
Slide 16
HP-RTM steel tool
HP-RTM steel tool
High quality surfaces
Sealed against 200 bar inner pressure
Integrated pressure sensors andtemperature sensors
Integrated electrical heating system
Integrated ejectors and robot positioningsystem
Slide 17
Murlock®
Insensitive to temperatures of up to 200°C
Pressure resistant up until 200 bar
Outstandingly easy to machine
Short delivery times
Chemically resistant to nearly all organic andinorganic chemicals
The Murlock® material gives the sealing ahigh elasticity within the operatingtemperature range, so that any unevennesson the surface or any foreign particles on thesealing surface can be compensated for
Slide 18
HP-RTM production cell
Slide 19
Facts of Process
Production data of Pre Series Part
Weight of final CFRP part: 226 gr
Weight reduction: 62%
Preform cycle time: approx. 120 sec
Shot time: approx. 5,5 sec (mold pressurecontrolled)
Curing time: 125 sec
Part price: approx 30-40 EUR
Slide 20
Optimization potential
Optimized Mold filling geometry
Optimized Mold Ending geometry
Preform cycle time optmization
Sand core cycle time with multi cavityproduction
Slide 21
Future potentials
Slide 22
Slide 23
Thank you for your attention.
Tobias JansenSales Manager Composites & [email protected]: +49 160 537 4864
Dan RozelmanCAA Senior Technical Sales [email protected]: +1 412 915 1414