presentation of presentation of axson axson shanghai ...cam.bue.edu.eg/presentations/15 may 2011...

1Matwind/ 2011 - Axson/BUE JNGentiliPresentation of Presentation of AxsonAxson Shanghai activitiesShanghai activities

MATWIND 2011 MEETING - AGENDA

INTRODUCTION to AXSON

CONSTRUCTION of LARGE MASTER MODEL (PLUGS) FOR WINDBLADES

General concept / Main Spécification. ( Chassis / backup /surface coating / preparation )

Surface coating alternative techniques : hand or machine application

• Manual paste / Machininable boards/ Extrudable Paste

• Equipment overview : CNC / extrusion• Equipment overview : CNC / extrusion.

Trouble shooting / Repairing / Preparing /finishing….

Question / answer

2Matwind/ 2011 - Axson/BUE JNGentili

MATWIND 2011 MEETING - AGENDA

PART 2 : LARGE DIMENSION MOULD MAKING

General concept ion / Main Spécification / Expected Productivity / Limitations.

Alternatives materials : Liquid epoxies/ Prepregs/othersAlternatives materials : Liquid epoxies/ Prepregs/others.

Alternatives techniques : Wet Lay up / Infusion.

Fabrics / Core fillers / Vacuum accessories

Preparation / repairing

QUESTION / ANSWER + CONCLUSIONQUESTION / ANSWER + CONCLUSION.



Head quarter : Cergy France6 production site12 subsidiaries.32 distributors.350 employees 60 M€ T°



Expertise = Formulation and production of thermosetting epoxy and polyurethane resins for thermosetting epoxy and polyurethane resins for multi-industrial applications

4 DIVISIONS

DESIGN / PROTOTYPING / MODELING / TOOLINGDESIGN / PROTOTYPING / MODELING / TOOLINGDIELECTRICSADHESIVESCOMPOSITES


INTRODUCTION to AXSONDESIGN / MODELING / PROTOTYPING / TOOLINGDESIGN / MODELING / PROTOTYPING / TOOLING

Automotive designAutomotive design

Ceramic waresTooling FRP molds

Glass and cristal wares

Toys


Metal sheet Stamping molds

INTRODUCTION to AXSONDIELECTRICS

Automotive Sensors : for engine management systems, automotive

technology, safety systems or

DIELECTRICS

Railway transformer encapsulation

gy, y yproduct enhancements

Coils

Airbag sensor encapsulation

Coils encapsulation for

transportation

Encapsulation of capacitors

Electronic lighting sensors

p p


Electrical and electronic resins

INTRODUCTION to AXSONSTRUCTURAL ADHESIVES

Adhesives for body parts and windows for transportation vehicles

and for limited series

STRUCTURAL ADHESIVES

and for limited series

Structural Adhesives for chassis of vehiclesStructural Adhesives for chassis of vehicles

structural bonding of lift doors

Solar panel bonding Railways interior parts bonding

Load-bearing mastic for insulation of LNG vessels


INTRODUCTION to AXSONCOMPOSITESCOMPOSITES

MARINE

AerospaceSports and leisure

MARINE

AXSON OFFERS A 360 ◦ SOLUTION :

DESIGN

TOOLING

PARTS

ASSEMBLY

LIGHTNESSSTRENGTHDURATIONAutomobileWIND ENERGY


ASSEMBLY

INTRODUCTION to AXSONWINDMILL SOLUTIONSWINDMILL SOLUTIONS

CAD design

AXSON = A to Z solution provider to wind blade makers

MODEL MOULD BONDINGPARTS


CONSTRUCTION of LARGE MASTER MODEL (PLUGS) FOR WINDBLADES

CONSTRUCTION STEPS > >>>>>>>>>>>>>>>>>>


CONSTRUCTION of LARGE MASTER MODEL GENERAL CONCEPT / DEFINITIONS

MODELGENERAL CONCEPT / DEFINITIONS

CROSS SECTION

COATING optionnal

CONTACT SURFACE Monobloc with backup

BACKUP STRUCTURE

CONTACT SURFACE - Monobloc with backup or added to backup ( slab /paste/…)

CHASSIS

A cohesive construction !!


CONSTRUCTION of LARGE MASTER MODEL CHASSIS > CONSTRUCTION ALTERNATIVE

MODELCHASSIS > CONSTRUCTION ALTERNATIVE

MDF sections

Sandwich pannelsassemblyassembly

Metallic welded.


CONSTRUCTION of LARGE MASTER MODEL BACKUP CORE > MATERIAL ALTERNATIVES

MODELBACKUP CORE > MATERIAL ALTERNATIVES

PU /EPO Machinable Boards Medium sdensity PU /EPO Machinable Boards Medium sdensity MONOBLOC++ Dimensionnal stability++ surface aspect

Cost-- Cost- - Time

PU FOAM + COMPOSITES LAMINATING.++ Cost efficient++ dimensionnal stability given by composites

Foaming equipment-- Foaming equipment- - Time

OTHERS: non detailed Wood /PS / Composites sandwichs...


CONSTRUCTION of LARGE MASTER MODEL BACKUP CORE alternatives

MODELBACKUP CORE alternatives....

•1 ) Metallic Chassis

•2 ) OSB Wood Sheets (Screwed/Bonded)

•3) Sealing layer : Epoxy resin EPOLAM 2015 on quadriaxial .

•4) BALSA Wood + Infusion Epoxy

•1 ) Metallic Chassis

•2 ) horizontal grids

•3) Pu foamed + machined

•4) composites coupling layer : 6 plies UD300gr/M2 + EPOLAM 2020 epoxy hand layg p y yup


MODEL

MASTER MODEL or PLUG CONSTRUCTIONBACKUP CORE CONCLUSION MODELBACKUP CORE CONCLUSION

Several options and combinations possible :

Metallic frame

PU foam or PS foam base

Epoxy/glass hand laminate

Sandwich MDF core with epoxy/glass laminate skinsSandwich MDF core with epoxy/glass laminate skins

Quality is determined by :

1. Dimensional accuracy and stability

2. Ability to support static weight

3 Surface adhesion and compatibility with3. Surface adhesion and compatibility withsurfacing material


CONSTRUCTION of LARGE MASTER MODEL CONTACT SURFACE ALTERNATIVE

MODEL

1 Manual application Polyester Putty surfacing material?

CONTACT SURFACE ALTERNATIVE

Advantages

Low material cost

Disadvantages

Too fast curing limiting area and thickness

Easily available in the market with many suppliers

g gapplied at once

High exothermy and shrinkage

Many manual repairs

Several layers to reach total thickness

N di i l t bilitNo dimensional accuracy nor stability

High density

E il d d f ki ldEasily damaged surface upon making mold

High toxicology


CONSTRUCTION of LARGE MASTER MODEL CONTACT SURFACE ALTERNATIVE

MODELCONTACT SURFACE ALTERNATIVE

2 Manual application EPOXY Putty surfacing material?

Advantages

Applicable in a single layer

Disadvantages

Tedious work to apply on large fDimensional accuracy and stability

Low density

surface

Some repairs and showing lines due to overlaps

Well proven products in otherindustrial design applications including chinese automotive market

p


MODELCONSTRUCTION of LARGE MASTER MODEL Surface coating alternatives EXTRUDABLE PASTE MODELSurface coating - alternatives EXTRUDABLE PASTE

3 Machine application SEAMLESS EPOXY PASTE (extrudable)

Advantages

Applicable in a single layer

Disadvantages

Requires investment in a g y

Dimensional accuracy and stability

Low density

specific metering machine

Seamless surface with even and smooth aspect

M hi bl ithi 24hMachinable within 24hrs

Well proven products in otherindustrial design applications includingg pp g

lowest toxicology in handling


MODELCONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE GENERAL PRINCIPLES MODELEXTRUDABLE PASTE GENERAL PRINCIPLES

See pics


MODELCONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE WINDMILL PICS MODELEXTRUDABLE PASTE WINDMILL PICS


MODELCONSTRUCTION of LARGE MASTER MODEL

AXSON Paste offer

SC 175 modelling paste SC 390 tooling paste

MODELAXSON Paste offer

Low density type

Plug making standard

High density type aluminium filled

High surface hardness .

High surface quality to minimizeEasy set up and process surface treatment

Tg of 90° after post curing

Elevated dimensionnal stabilitySC 380 tooling pasteIntermediate density

Good mechanical features

Cost efficient

Run on TDS

Run on TDS

Cost efficient.

Easy and effective to apply.

Run on TDS

R TDS


Run on TDS

MODELCONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE ISSUES MODELEXTRUDABLE PASTE ISSUES

LOOKS SIMPLE !!!!!LOOKS SIMPLE !!!!!

NO. !

COHERENCE OF WHOLE PLUG SYSTEM ( Chassis + Backup structure)ENVIRONMENTAL ISSUES ( Space, ventilation, Temp regulation etc..)EQUIPMENT OPERATIONNALEQUIPMENT OPERATIONNALLOGISTICS ( several sections + shipment)

Paste.

Applicator skillsThickness control.

RepairingRepairingPost treatment

Finishing


……

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE SOME APPLICATION ISSUES EXTRUDABLE PASTE - SOME APPLICATION ISSUES....

APPLIED TO LARGE AREAS >10 M2…..

1° Thickness Control = Machine + operator skills + type of nozzles

The application itself : nozzle verticaleThe application itself : nozzle verticale

Overlapping seams




2° Exhotermy / Material Dilatation - Shrinkage prévention

The application itself : dilatation lines

+/-20mm




3° Post curing….for higher stability + Temperature resistance (depending on li ti )application)

Heating Blankets or Heating tunnel ( bagging ) Heating Blankets or Heating tunnel ( bagging )


CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE TROUBLE SHOOTING EXTRUDABLE PASTE - TROUBLE SHOOTING....

Each scanned trouble claim forEach scanned trouble claim for well known solution (Experience).

Extruding on large dimension 1 4is complex !

25

2

36


CONSTRUCTION of LARGE MASTER MODEL REPAIRING /COMPLETING / PREPARING REPAIRING /COMPLETING / PREPARING

1. Repairing cracks holes voids cavities……Material on itself !!!

2. Repairing small surface defects : porosities >>>>Polyester putty

3. Sanding when needed.

4. Wax + semi permanent or permanent solution application.p p pp


CONSTRUCTION of LARGE MASTER MODEL FINISHING > PREPARING FOR MOULDING NoteFINISHING > PREPARING FOR MOULDING Note

The ultimate finishing of the master model is possibly done by spraying / ulltra thin layer of different type of materials like :ulltra thin layer of different type of materials like :

Vinylester spray filler or Gelcoat, P l l t l tPolyvalent lacquer system.Polyurethane Paint system High Gloss.Epoxy coat sprayable……

After paste surface deep cleaning + eventual sanding, for,

Making sure of Air TightnessSurface absolute regularityGlossy and Shiny for better release and mould qualityGlossy and Shiny for better release and mould quality


MODEL

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE MACHINES

2-components epoxy thixotropic system

Pumping Metering dispensing

MODELEXTRUDABLE PASTE - MACHINES

Following plates using gear pumps

Static mixing nozzle for easy maintainance

Some interesting options… So e te est g opt o s


CONSTRUCTION of LARGE MASTER MODEL CNC 5 Axis Center MODELCNC 5 Axis Center MODEL


MOULDCONSTRUCTION of LARGE MASTER MODEL READY FOR MOULDING !!! MOULDREADY FOR MOULDING !!!


New release Axson brochure for wind blade manufacturing MOULD


WINDMILL PLUGS and MOULDSCONCLUSION

OPEN DISCUSSION - QUESTION

THANK YOU ALL


presentation of presentation of axson axson shanghai ...cam.bue.edu.eg/presentations/15 may 2011...

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