integration of feat ures into parts made from ...€¦ · in aim of t serts and ning type d levels...
TRANSCRIPT
Benj
Thein structsuch assignificacomplexfeaturesof thoseshort ainvestighow the
Injecfor the papplicatto 0.5 mparts [2suitablemechanalloys. Sthermopcharacteterm loaconsidepart’s ereinforce
INTEGRT
njamin Han
2 Institu
rmoplastic ctural compo
s woven fabantly. Howex structuress that are coe can be aand long fiation on ov
ese results c
ction moldinproduction otions [1]. Wimm (injectio]. Although
e for main nical propertSecondly, thplastic matreristic is criads are appered materiaentire lifecyement.
Figure 1: S
RATION THERMO
OV
gs1, Christ
1 Fraute of Vehicl
composite monents. Esprics or unid
ever, due ts such as rommonly pa
achieved witber-reinforc
vermolding ocan be trans
ng and comof complex ith the stand
on molding) this materiastructural
ties, and eshe viscoelasix and hencitical with replied. As a cals is that mycle. This o
Selection of co
OF FEATOPLASTI
VERVIEW
toph Esch1
aunhofer Insle System T
materials hapecially semirectional tato their limribs is not art of complth continuo
ced materiaof unidirectisferred to m
I
pression mshort and ldard varianand 40.0 m
al class is scomponen
specially stifstic behavioce the overaegard to strconsequenc
mechanical poftentimes
ommon continu
Page 1
TURES INC, UNIDI
- W AND C
, Manfred
stitute for ChTechnology,
Abstrac
ave lately bmi-finished papes have aited drapabfeasible. Thlex technica
ous-fiber-reinal. The suonal tape in
more comple
ntroducti
olding are tong fiber-rets of these mm (D-LFTsufficient for nts. Two mffness, cannor of polymeall short orructural appce, one majperformancecannot be
uous fiber-rein
NTO PARIRECTIO
CASE STU
Reif1, Timo
hemical Tech Karlsruhe In
ct
been considproducts wita high potenbility and fhis paper pal applicationforced strubsequent cnserts. In coex compone
ion
today’s stateeinforced theprocesses f
T compressir non- or semmain factorsnot competeers results ilong fiber-r
plications, injor requireme and tolera
ensured w
nforced semi-fi
RTS MADNAL TAP
UDY
o Huber1, F
hnology nstitute of Te
dered increath continuountial to increflowability tpresents anns. It showsuctures by case studyonclusion, ants.
e-of-the art ermoplasticfiber lengthson moldingmi-structuras cause the with modein limited crreinforced mn which statment that neances are suwith solely
finished produc
DE FROMPE
Frank Henn
echnology
asingly for aus fiber-reinase part pehe forming
n overview s how implecombining
y presents an outlook is
process tecc parts in higs of approx
g) are achieal applicatiohis limitatioern steel or reep resistamaterial [3, tic and dynaeeds to be ustained thr
short or l
cts (CFRSFP)
M
ning1, 2
application nforcement erformance of highly of desired
ementation them with a related
s given on
chnologies gh-volume
ximately up eved within ns it is not
on. Firstly, aluminum
ance of the 4, 5]. This amic long-fulfilled by
roughout a ong fiber-
Oneproductsof this mstructurepart desthe conmatrix. effect is
Figure 2
Nev(CFRSFflow caplittle surparts. Asolutioncircumsapplicat
The further epresenteparticulacorrespocompresmateriacreates functioncreatingprocess
e approach s made frommaterial claes and unidsigns to be atinuous fibeAs a result
s illustrated i
2: Illustration of
vertheless, FPs) is theipabilities arerrounding m
Although thes usually re
scribed overtions.
Fig
question thextend the ed in this par, local coond to higssion moldil surrounds
a part’s nalized areag structural s combinatio
to overcomm preimpregass, namelydirectional taadapted to ers. That w, creep behin Figure 2.
f the difference
one dowr limitation e limited du
matrix materese shell strequire an arview of the
gure 3: Selecti
hat arises infields of ap
paper combontinuous fhly loaded ng. After thethe CFRSFoverall ba
as. The conintegrity an
on, also kno
me this bagnated cont
y randomly ape layups.the relevan
way loads ahavior of pa
e in creep beh
nside of to produce
ue to high firial. Compreructures are
appropriate e enormous
ion of features
n this contexpplication foines multiplfiber-reinforspots of a
e injection oFP inserts inase structutinuous fibend creep reown as Tailo
Page 2
rrier is the tinuous fibeoriented fib
. However, t load cases
are carried aarts is no lo
havior for shor
continuoushighly com
iber volumeession molde feasible fodegree of is variety of
s commonly in
xt is how theor thermoplale processerced insertsa part andor compressn the final coure, which ers on the oesistance oored LFT [2,
applicationers. Figure 1ber mats, wimplementins. Forces nealmost enti
onger gover
rt (left) and con
s fiber-reinmplex geome fractions (ding is usedor a certainintegration f possibilitie
ntegrated in tec
e above staastic advan
es bringing s are posi are then sion processomponent. T
includesother hand nly were it , 6], is prese
n of thermo1 lists the mwoven fabricng this kindeed to be trrely by the rned by the
ntinuous (right)
forced semmetries. Drap
usually 40-6 to form 3-d
n range of aof featureses that can
chnical plastic
ated facts arnced compotogether thetioned in tcombined s step, shorThis short ageometricaare positionis needed.
ented in Fig
oplastic semmost commocs, fiber-rov
d of materiaransferred d
fibers instematrix mat
t) fiber-reinforc
mi-finished peability an60 % vol.) adimensionalapplications. Figure 3 p
n be found
c parts
re brought tosites? Thee benefits othe mold awith injecti
rt/long fiber-and long fibeally highly ned in the l. A schemaure 4.
mi-finished on variants ving-based ls requires
directly into ead of the terial. This
ced material
products nd material and hence l, shell-like , technical provides a in today’s
together to e approach of each. In areas that ion and/or -reinforced er material
complex, load paths atic of this
Figu
Oneadhesioof the dcertain processfollowingunidirec
Materia
WiththermopselectedmoldingCelestramateria
UD-GF/POM
POM
For injectionto polym
ure 4: Creating
e necessity on between described hextent, loa
sing stronglyg sections p
ctional (UD)
als
h the aboveplastic as md. The unreg grade, Tian CFR-TPls are summ
Density [g/cm³]
1.92
1.41
POM procn barrel of emer degene
g thermoplastic
for functionthe insert a
hybrid compads can bey depends present an itape.
e stated focumatrix mateeinforced mcona Hosta
P POM-GFmarized in T
Table I: Ma
Melt Temp.
[°C] c
[%
166
166
cessing, teme.g. more thration and a
c advanced co
nalized contand the funcposite solute transferreon the choinvestigation
E
us on strucerial. In a material foraform C27060 (UD-GF
Table I.
aterial properti
Fiber content
% weight]
60
-
mperatures an 20 min @
associated o
Page 3
omposites with
tinuous fibectionalizatiotions. Only ed in betwsen procesn related to
Experimen
tural applicafirst invest
r over-inject021 (POM)F/POM) is
ies of the inve
Tensile strength
[MPa]
940
65
above 230@ 210 °C noutgassing o
h integrated fe
er-reinforcedn material. if interface
ween [7-10]sing paramover-inject
ntal
ations, this tigation a tion moldin) [11]. For
used [12]
stigated GF/P
Young’s modulus
[GPa]
28
2.9
0 °C as weneed to be aof formalde
atures using p
d thermoplaThis is cruc
e autohesio]. Whether
meters. Relaion molding
research fopolyoxymet
ng is the lothe unidire
. Material
POM and POM
Flexural modulus
[GPa]
28
2.8
ell as dwelavoided [11]hyde.
process combi
astic parts iscial to take an is establi
this is acated to this g of inserts m
ocuses on athylene copow viscosityectional tapproperties
M
Elongationat break
[%]
2.25
17
lling times ]. This is req
inations
s sufficient advantage ished to a chieved in these, the
made from
a technical polymer is y injection pe, Ticona
for these
n Shear strength
[MPa]
-
62
within the quired due
Specim
Lap UD-tapefollowing
8-plyunif
In geis supecomparatest staunreinfoguidelin
Proces
For RELAY In a subthese inquartz hOnce pseveral curves othermal
Experi
Relacritical interfaciprocessfactors orthogo(sets) apoints. Wtempera
mens for la
shear teste inserts ang layup is in
y quasi-isoform in-plan
eneral, lap serimposed bative studieandard speorced maternes. The spe
ssing Equi
manufacturtape-laying
bsequent stnserts to deheaters thatreheating isseconds a
of the UD inimaging ca
mental ma
ated to the parametersial strength.sing paramecan be connal L27 exp
are tested wWith regardature after p
ap shear t
ting is perfnd overmolnvestigated:
tropic laminne material p
shear testinby bending
es that are reecifically focrial, the preecimen geo
ipment an
ring the UDg process. Tep, two inseesired tempt are mounts finished, hre needed nserts are damera.
atrix desig
introductions for overm. Using a fraeters (factorntrolled durperimental m
with six replid to the UD-preheating b
esting
formed withlded, unrein:
nates with properties.
ng is not ideg stresses elated to mocusing on
esented resmetry is sho
Figure 5: M
nd specime
D-tape inserThese blankerts at a timperatures isted to the iheaters areto remove
determined w
gn
n of this pamolding of Uactional facrs) are varieing the promatrix incluications. Ta-insert temp
but to the ins
Page 4
hin this stunforced ma
a (0, 90,
eal to determwithin the ore practicathe combiearch usesown in Figu
Modified lap sh
en produc
rts, tape layks are then me are put is realized unjection mo
e removed athe heatingwith a Testo
aper, the maUD-tape in
ctorial screeed on three ocess and cuding one ceable II lists tperature Te,sert temper
udy to evaatrix materia
+45, -45)s
mine a specbond line.
al load casenation of c
s DIN EN 14re 5.
hear specimen
ction
yups are firconsolidatento the injeusing two eolding machand the oveg unit and too 845 infrare
ain aim of tserts and
ening type dlevels eachcan be adjuenter point the investig the listed l
rature after t
luate the inal. For the
configuratio
cific materialHowever,
s. Due to thcontinuous 465 [13] an
n
rstly produced before Uection moldinexternal 40hine (Ferromermolding co close theed pyromet
this study istheir influe
design of ex. Attention i
usted directrun. All par
gated factorlevels do notool closing.
nterfacial sUD-tape in
on, offering
l constant sit is well
he fact that tfiber-reinfo
nd DIN 532
ed using FUD-inserts ang tool. Pre
00 watts infmatik Milacrcycle is stare tool, surfater and a FL
s to identifynce on the
xperiments (is paid that tly. This resrameter coms and factoot refer to th.
strength ofnserts, the
g relatively
ince shear suited for there is no orced and 81 [14] as
iberforge’s are cut out. eheating of frared (IR) ron K110). rted. Since ce cooling
LIR SC600
y the most e resulting (DoE), five all chosen
sults in an mbinations or level set he surface
Factor →
Levels ↓1
2
3
UD-tap
As sthe mom8 ± 2 s surface the envsuitablecurves frepresewithin th
Sumwas det
Results
PrioPOM m4 mm/m
Fouin Figure
1. Fai
Tabl
→ te
↓
2
3
pe insert c
stated in thement in whelapses frotemperatur
vironment ae heating timfor Te = 170nted by a h
he determin
mmarized fotermined to
s of lap sh
or to testingmatrix [15]. min on a Heg
r main failue 7 and are
lure of the
le II: Overview
Tool emperature
TW
70 °C
90 °C
110 °C
cooling cur
e prior sectiohich the oveom removal re of the insand the toomes for vary0 °C in relathorizontal bed timefram
or all combibe 4 – 7 %
hear testin
, specimensSubsequen
gewald & Pe
re modes ce characteriz
overmolded
w of investigate
Meltempera
at nozTm
200 °
210 °
220 °
Result
rves
on, Table IIermolding tof the IR h
serts decreal temperatuying combinion to the th
black line. Tme of 8 ± 2 s
Figure 6: Coo
inations of within the p
ng
s are storednt lap sheaeschke – In
can be identzed as follow
d, unreinforc
Page 5
ed process pa
lt ature zzle
I
°C
°C
°C 1
ts and Dis
lists desiretakes placeheaters untases influenure level TW
nations of Three levels
The yellow as.
oling curves of
Te and TW,processing w
d for 7 daysar testing onspekta 50 t
tified for couws:
ced polyme
rameters (fact
Injection speed
v
60 cm³/s
90 cm³/s
120 cm³/s
scussion
ed UD-tape e. In generail injection nced by theW. The perf
Te and TW leof TW as anarea shows
f UD-tape inse
, the insertswindow of a
s to ensureof overmoldtable univers
upons in thi
er within the
tors) and facto
UD-tape itempera
Te
130 °C
150 °C
170 °C
insert surfaal, an approis started. W
e temperatuformed inveevels. Figurn example. T the resultin
erts
s’ surface ta single leve
e completedded specimsal testing m
s test series
e overlappin
or levels
nsert ture
Hold
C 5
C 7
C 9
ace temperaoximate timWithin this re gradient estigation dre 6 illustratTherein the ng insert te
temperatureel combinati
d crystallizamens is permachine.
s. They are
ng area. Th
d pressure p
500 bar
700 bar
900 bar
ature Te for meframe of
period the relative to
determines tes cooling Te level is
emperature
e deviation on.
tion of the rformed at
illustrated
he material
inte
2. Fai
3. FaiUD
Figure 8force Fm
varying shown f
The evaFmax witspecimestandarddeviatio20.1 %)
Relatedperformand (13Both gro(7, 8, 9)kN and 60.9 %.
erface is the
lure at the e
lure at the -insert’s out
8 shows anmax, at which
hold pressfor each gro
aluation of ghin a singleens per sed deviation
on of results). For Te on
to the amance and fa3, 14, 15), woups are ba) and (10, 1
3.7 ± 0.40
ereby not ful
edge of the
edge of thter ply occu
Figure 7:
n overview h specimensure to impoup.
gathered rese parameteret. Overall varies more
s is therebylevel 2, in c
chievable ailure modewhich perforased on Te 1, 12), are T kN, which
Fig
lly develope
fully develo
he fully devurs (right).
Typical failure
of all paramns failed. Reprove reada
sults showsr set. This dmean devie uniform buy related tocontrast, gro
interfaciale are highlyrm the worslevel 1 com
Te level 3 cocorrespond
gure 8: Summa
Page 6
ed (left)
oped materia
veloped ma
e modes for te
meter setsesults are gability. Furt
s an inconsideviation is iation was ut still on a
o combinatiooup variation
strength Faffected by
st with meambinations. ombinationsds to an inc
ary of results f
al interface
aterial inter
ested lap shea
and relatedrouped arohermore, th
istent standcalculated f10.0 %. Whigh level oons with Te
ns are less
max, Figurey Te. This isan Fmax of 2
In contrasts. For thesecrease in m
for lap shear t
(middle).
rface. Local
ar specimens
d mean valuund specifiche most ty
ard deviatiofrom a numWithin grouof 7.5 – 20.1e on level 1pronounced
e 8 furthers e.g. appar2.4 ± 0.48 k, the two to
e groups Fma
mean interfa
esting
l delaminat
ues for the c parametepical failure
on of 0.9 – ber of two tped param
1 %. Highes1 and level d with 7.5 –
rmore illustent for grou
kN and 2.3 op performinax results in
acial strengt
tion of the
maximum r sets with e mode is
21.5 % for to six valid
meter sets, st standard
3 (12.3 – 9.8 %.
trates that up (1, 2, 3) ± 0.37 kN. ng groups, 3.5 ± 0.43
th of up to
The is createmain gounreinforesults. temperalevel 3, would b
Figure 9:
To sorder topressure
Discus
Forestrengthdeviatioof the pthe spechigh sta
The 8 ± 2 s of highedeviatiomachineTe.
ThicconsolidWith theinserts. sample thin injebe remocausing3, excescombinadeclared
above stateed with the overning paorced POM
This is expature until rea constant
be for TW an
Variable impo
sum up, the o create suffe was ident
ssion
egoing presh of overmoon of 10.0 %parameter scimen prod
andard devia
investigatiocorrespondest influenc
on to a minime would sig
ckness standated blanke mold caviHowever foends. This
ected materioved (See F
g injected massive damaation with vd as scrap.
ed effect of DoE softwa
arameter to. In additioplained by teaching theTm results id v on level
ortance plot (V
results valificient interfatified to have
sented resullded UD-tap
% and up to 2ets 3, 9 anuction procations. They
on of surfaing to 4 – 7
ce on interfamum. Imple
gnificantly im
ndard devik. With a noity depth beor some inscauses twoial is presseFigure 10, laterial to hit
age of the inv and Tm o
Te is moreoare MODDE
o influence on, TW interthe fact thae interface on higher effl 1.
VIP) for the infl
date that a acial strenge no identifi
ts determinpe inserts. H21.5 % for ad 10 is calcess were idy are discus
ce tempera7 % deviatioacial streng
ementing a fmprove repr
ation of Uominal insereing 3.0 mmserts, thickno issues for ed into the geft). Secondt the upper nsert occurson level 3.
Page 7
over validateE (see Figuinterfacial
racting withat this combof the UD-tafective temp
fluence of proc
suitable comth. Tm,eff is tiable effect
e the most However, daa single parculated by odentified to ssed in the f
ature coolinon for the agth it is essfully automaroducibility
UD-tape insrt thickness m, this varianess variatiospecimen mgap betweedly for the ofront face e
s (See FiguSamples s
ed by the vaure 9). In thistrength of v also sho
bination direape insert.peratures w
cess paramete
mbination othereby direand was ex
important pata analysisrameter set.only 2 validcause this lfollowing pa
g curves reactual Te valsential for fated heatingof preheatin
serts was of 2.0 mm
ation is balaon is up to manufacturinn insert suropposite caedge of the re 10, right)showing on
ariable impois plot, it is f UD-GF/POows a signectly influenFor exampl
when the ins
ers on the achi
of Tm,eff and Tectly connecxcluded in th
process paras also revea Furthermo test sampllimited repro
aragraphs.
evealed a plue. With Te
future expeg system inng, hence r
up to 8.6this is equ
anced with s0.14 mm e
ng. Firstly, frface and mase, the inseinsert. Espe). This was ne of these
ortance plotevident tha
OM with ovificant impa
nces the injele, if TW andert is hit (Tm
ievable interfa
Te is essentcted to TW ahe VIP.
ameters forals an overare, standardles. Severaoducibility r
processing e being the
eriments to the injectioreducing de
% within ivalent to ± shims undeeven betweefor inserts th
mold cavity aert is slightlyecially with Teven more
e defects h
t (VIP) that at Te is the vermolded, act on the ected melt d v are on m,eff) than it
acial strength
tial in nd v. Hold
r interfacial ll standard d deviation l details in
resulting in
window of parameter reduce its
on molding eviation for
a single 0.17 mm. rneath the en the two hat are too and cannot y too thick Te on level
e distinct in ave to be
Onetemperato a laceffect wfor Fmax the resucombinelow withto creathigher adeviatio
Relafront fatemperaeffect ismateriaspecimeapproxim
In cointerfaciconnectlevel cloinjectedinsert. Astudy, vrequiremin Te to
The parameunreinfoimportainjectionhence rprovide polymer
e further reaature resultek of proper
with an averaof 16.72 ±
ulting interfaes Te on levh regard to te a certainaverage Fm
on of 7.5 %.
ated to TW ace. Due toature in thiss avoided bl. However,ens with lowmately 1.5 m
onclusion, tial strengthted to high rose to but s material. A
Although thivariation of ament for is ta minimum
presented ters on th
orced polymnce to ensun speed andresults, althsufficient h
r chains on
ason for sced in multipautohesion
age numbe4.9 %. The
acial strengtvel 1 with TW
sufficient aun degree ofmax compare
and the speo heat trans area is lowby an inser for the fronw levels ofmm of the in
the conduct Fmax. Howrisk of specstill below mAn increases method reachieved reto implemen.
research whe achievamer. Insert ure proper d their interahough to a heat in the micro scale
Figure 10: D
crap coupole coupons
n. Especiallyr of only 3.5e importancth is further W and Tm onutohesion, tf cohesioned to grou
ecimen desnsfer from wer than in rt width of nt face this ef first and fnterface.
ted test seriwever, inserimen damagmelting poined tool tempesults in ap
esults was dnt automate
work investigable interfapreheating autohesion
actions alsomore limiteinterface so
e [7-10].
Page 8
amaged lap sh
ns is relatethat had no
y parameter5 valid specce of sufficieunderlined
n level 3 as the injectedin the interp (1, 2, 3)
sign, anothethe insert the residua35 mm co
effect cannoforemost Te
ies shows art surface tge. One altent and to geperature furproximatelyetermined t
ed handling
Outlook
gated the infcial strengtemperatur in the inte
o influence thed extent. o that autoh
hear specimen
ed to Te ono sufficient ir groups (1,cimens and ent temperaby parametwell as v o
d melt providrface. This ) but also
er effect is into the r
al overlappompared to ot be avoidee and TW s
a dominant temperatureernative rouenerate therther suppo
y 13 % loweto be signific and/or hea
k
fluence of vgth of UD-re was thererface. Toolhe effectiveIn general, hesion is po
ns
n level 1. Tnterfacial st, 2, 3) and (high averag
ature in the ter group (2
on level 2. Ades enoughis not only by the low
observed crelatively coing area. Fthe 25 mm
ed. Consequshowed no
effect of Te es well aboute in this coe remaining orts to avoider absolute Fcantly loweating system
various injec-tape inserreby determ temperatu
e temperaturthe essent
ossible, cre
This insert ptrength for t(13, 14, 15)ge standardmaterial in
25, 26, 27). TAlthough Te h heat to the
apparent bwer average
close to the older tool, or the side m of the ovuently, multcohesion i
to achieve ove melting ontext is to s
required hd rapid cooFmax values r. In any ca
ms to reduce
ction moldinrts and ovmined to bere, melt temre in the intetial requirem
eating interm
preheating esting due ) show this d deviation terface for This group is critically e interface by 20.1 % e standard
UD-insert the insert faces this
vermolded tiple tested in the first
maximum point are
select a Te eat by the ling of the within this se, a main e variation
ng process vermolded, e of major mperature, erface and ment is to mingling of
F
WithCFRSFextend demonsReferrinparts inrovings)producttechnolo
Gratsupport
Figure 11: Dem
h the abovePs is gainedbasic expe
strator part tng back to Fncorporating). With the ion, such pogies and p
titude goes in establish
monstrator par(fibe
e presentedd. The inveeriments to that incorpoFigure 3, thg features s
future goaphysical de
processes.
to the Freehing the Fra
Meta
Fibe
rt showcasing er-rovings and
d experimestigated promore com
orates a UDe demonstrsuch as loal of providi
emonstrator
Ack
e State of Baaunhofer Pro
al inserts
er‐rovings
Page 9
an over-injectd metallic load
nts, a fundocessing wimplex struct
-tape top larator furtherad transmisng thermoprs are impo
knowledge
avaria as woject Group
tion molded UD transmission
damental unndows for stures. In th
ayer with cormore showssion insertsplastic advaortant to s
ement
well as the CFunctional
D-insert and in points)
nderstandinspecific mathis context,mplex overm
ws an outloos (Metal be
anced comphow overa
City of AugsbLightweigh
ntegrated featu
ng for overmterials are e Figure 11molded rib s
ok to highly earings, woposite in higll feasibility
burg for thet Design.
ures
molding of essential to
shows a structures. integrated
ound fiber-gh-volume y of novel
eir financial
Page 10
Sample References
1. Jud, Thilo, Ingo Harzheim, Hans-Dieter Meinert, & Roland Pettirsch-Tisler, Köngen, “Kunststoff-Ersatzradnykden – Langfaserverstärktes PP im Automobilbau,” KU Junststoffe Online-Archiv, Carl Hanser Verlag, München, Jahrg. 90 (2000) 4, pp. 108-112.
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