rethink: cfrp recycling and sustainability near-net-shape ... · casting, composite and processing...
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Fraunhofer Research Institution for
Casting, Composite and Processing Technology IGCV
reTHINK: „CFRP – Recycling and Sustainability“Near-Net-Shape fabrication-technologies for CFRP
Dipl.-Ing. Alexander Schug 16.-21.11.2016
18.11.2016 @ KMITLKing Mongkut's Institute of Technology Ladkrabang,
Central Library 5th floor, Chalongkrung Road, Ladkrabang District, Bangkok 10520
21.11.2016 @ UCSIUCSI University, North Wing Campus, Taman
Taynton View Cheras, Lot 12734 Jalan Choo Lip Kung, 56000 Kuala Lumpur
16.11.2016 @ JEC AsiaSUNTEC International Convention & Exhibition Centre,
1 Raffles Boulevard, Suntec City, Singapur 039593
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AGENDA
Motivation for Near-Net-Shape fabrication
Resource efficient production technologies
Automated Tape Laying (ATL)
Automated Fibre Placement (AFP)
Forming simulation
Challenges
Conclusion
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Motivation for Near-Net-Shape fabrication
Resulting scrap with different fabrication technologies
Quasi-isotropic layup: [0/90/+45/-45]s
Tape width has an influence on the resulting scrap
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Source: automobilemag.com
ATL, 50 mm width: 15.84% AFP, 6.35 mm width: 4.04%Conventional: 41.01%
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Automated Tape Laying – Fiberforge RELAY®2000Specifications
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2D-layup, any fibre orientation possible
Max. layup size: 2 m x 2 m
UD-Tape width: 50-150 mm (infinitely variable)
Ultrasonic spot welding
Combination of any fibre and thermoplastic matrix (e.g. PP, PA6, PEEK)
Little scrap through tailored layup
Integration in automated process chain possible
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Automated Tape Laying – Fiberforge RELAY®2000Process chain
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IR
ATL-Layup
Transfer
Consolidation
Pre-heating Transfer
Forming
IR
ATL-Layup
Transfer
Consolidation
Pre-heating Transfer
Forming
IR
ATL-Layup
Transfer
Consolidation
Pre-heating Transfer
Forming
IR
ATL-Layup
Transfer
Consolidation
Pre-heating Transfer
Forming
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Automated Tape Laying – Fiberforge RELAY®2000Example parts
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MAI Plast demonstrator (PA6/CF)Forming demonstrator (PPS/CF,
Premium Aerotec GmbH)
Truck service hatch (PA6/CF)
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Automated Fibre Placement – Coriolis CompositesSpecifications
Manufacturer: Coriolis Composites
Feasible structure size: length 7 m, diameter 3 m
End effector: laying head with 8 x ¼“ tows
Near-net-shape, material efficient, composite lightweight structures
Multi-material applications:
Thermoplastic prepreg systems (e.g. PA, PPS, PEEK)
Thermoset prepreg systems
Dry-fiber placement (binder yarn)
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Automated Fibre Placement – Coriolis CompositesProcess chain
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3D - Fibre placement
2.5D - Fibre placement
Autoclave curing
Forming and consolidation
Final 3D-Part
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Automated Fibre Placement – Coriolis CompositesConcept for series production and realization
LuFo IV Projects Azur/AZIMUT/RoCK
A350-1000 Door Surround Structure (DSS)
in cooperation with
Goals:
Substitution of Ti-parts with CFRP
Increased performance
Significant cost reduction
Weight reduction
Development in respect to time schedule
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Automated Fiber Placement – Coriolis Composites AFP process for curved frames: the result
85% CFRP
Weight- and cost savings
JEC Innovation Award 2016
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Source: http://www.augsburger-allgemeine.de
Source: http://www.premium-aerotec.com/Binaries/Binary7769/Premium_AEROTEC_03.jpg
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Combination of ATL and AFPThermoplastic MAI Plast (key project MAI Carbon Cluster)
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Development of cost-efficient technologies for automated processing of thermoplastic high-performance fibre reinforced composites for high volume production
Realization load-path optimized, locally reinforced semi-finished products
Combination of ATL and AFP technologies for efficient manufacturing
Demonstration of an efficient process chain for direct in-mould forming and functionalization of TAFP preforms
Automated FibrePlacementLoad-path optimized localreinforcements
Fiberforge RELAY® Automated Tape LayingHighly productive, tailored performing
Load-path optimized, generic skin structure
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How to generate the flat layup contour of a 3D-part?The “missing link”
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http://steamregister.com
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Forming Simulation Generating a Near-Net-Shape layup
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Forming simulation (AniForm)Definition of the part boundary Back-forming and contour creation
Layup pattern for the ATL-process Final part with less scrap
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Challenges
ATL/AFP + Forming
Fibre orientation
Wrinkles
Gaps
Surface quality
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AFP
Path programming
Gaps/Overlaps
Collision analysis
Simulation
Material characterisation
Shear rate and temp-erature dependency
Computational effort
Source: Zenker, T.,et al., ECCM17, 2016
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Conclusion
Near-Net-Shape fabrication can reduce up to 40% of scrap during production
Automated Tape Laying and Automated Fibre Placement are suitable technologies to produce Near-Net-Shape preforms highly automated
As a result higher sustainability and lower costs can be achieved
Forming simulation can be used to replace expensive trial and error experiments for generating the contour and improve the part quality
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Source: http://www.aniform.com
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Near-Net-Shape fabrication-technologies for CFRPContact us
Fraunhofer IGCVAm Technologiezentrum 286159 Augsburg, Germany
Dipl.-Ing. Alexander SchugPhone +49 821 / [email protected]
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