slc lab opening
DESCRIPTION
Sirris Leuven Gent Composites Application lab - general introductionTRANSCRIPT
Welcome tothe official opening
of the SLC-LabApril 26, 2012
Program of the day
13h30 SLC-Lab and beyond - trends and insights Hans Vercammen, Sirris ; Ignaas Verpoest, KU Leuven ; and Joris Degrieck, UGent
14h00 Basalt fiber composites Pauline Koslowski, Basaltex
14h30 Collaborative innovation for high volume composites John Hobdell, Huntsman Polyurethanes
15h00 Specification for industrial robots in CFK-machining Otto Kellenberger, KUKA Robotics
15h30 Composites: great opportunities with tough challenges Jan-Anders Månson, EPFL
16h30 Official opening of the SLC-Lab Guided tours and demonstrations
18h00 Networking / cocktail buffet
Welcome tothe official opening
of the SLC-LabApril 26, 2012
Why an application lab? Why composites? Why here?
Hans Vercammen
Business unit manager at Sirris
Results Survey
Survey(*) with 400 companies from the technological industry in Belgium showed that
Industry seeks: Capacity for product development
New ideas for new product development
Infrastructure for new product development
Sirris answer Application Labs
(*) Net Promotor Score survey, jan 2011
A multidisciplinary lab where companies can test theirinnovations at an almost industrial scale using newtechnologies in take off, without having to make investments
Many unconnected stakeholders
Material Processing Product
Lab
Prot
otyp
ing
Indu
stria
l
Fabricatorand itsvaluechain
OEM
UGent MMSKU Leuven Associatie
lack of application lab
Engineering Offices
Materialproducers
Many connected stakeholders – application driven
Material Processing Product
Lab
Prot
otyp
ing
Indu
stria
l
Fabricatorand itsvaluechain
OEM
UGent MMSKU Leuven Associatie
Engineering Offices
Materialproducers
An open initiative by KU Leuven, UGent and Sirris
Application Lab inspired by …
industrial (but private) application labs Closed-shops: Umicore (solar cells), Bekaert (tires), CTC (EADS), and
many others
Semi-open: Agfa-Labs
the “Fablab” initiatives world wide, prof. Neil Gershenfeld, MIT E.g. FabLab Leuven
public-private initiatives CFK valley, Pôle Plasturgie de l’Est, Carbon Composites ev, ...
An application lab brings technology to companies
Focused on products/services & their industrial value chain
• Enabling:
• Players in the value chain to see the effect of their product/contribution on the end product
• Interaction between players in the value chain with the OEM
• Stimulate innovation outside the typical client-supplier relationship
• Create technology awareness with OEMs
• Targeting industrial time to market: 0 to 18 months
An application lab brings technology to companies
Strongly application oriented
Working on a test sample?
Or would you prefer working on a real world or close-toreal world product?
An application lab brings technology to companies
Low entrance level
Value proposition of Sirris
Find appropriate funding or research partners
Think together with entrepreneurs, speak the same language
Bridge between R&D and industrial applications
Hands-on engineers experienced with new technology …
And the equipment to prototype it …
And the facilities to evaluate it.
Mission
Create composite innovations for:a. Material producers
b. Composite part fabricators
c. Designers of composite parts, OEMs
Provide the industry with tangible solutions
Low-threshold development center
Short term innovation trajectories
competitivecompositeproducts
SLC-Lab Partners
...2007
2012
Launch 2009
From your idea to a tangible product
Conceptual designmaterial, process
tooling, series, cost
Structural design Virtual prototype
Process development
Validationprototyping, testingproduction planning,
cost estimation
ProductFeasibility study
SLC-Lab Equipment Fontijne press with preheating station (1):
thermoplastic and thermoset
Resin infusion systems (2)
Curing oven (3)
Vacuum pumps and oven
Mould heating systems
Paint booth
Chemistry laboratory
Workshop
(1)
(2)
(3)
SLC-Team
- Markus Kaufmann
Lab Manager
- Aart Van Vuure
Project Engineer
- Linde De Vriese
Project Engineer
- Bart Waeyenbergh
Project Engineer
- Guy Lambert
Technician
- Jonas Van De Winkel
Technician
- Open position
Project Engineer
Celebrating over 30 years research in composites
at KU Leuven
Prof. Dr. Ignaas VerpoestKU Leuven
Composite Materials Group @ KU Leuven
The Composite Materials Group at KU Leuven: achievements over 30 years
The research approach at CMG: From materials to processing and products
From nano- to macro-scale
Some examples of research in the four focus areas
CMG-KU Leuven in 2012 and beyond…
CMG-KULeuven achievements: 1981- 1990
Research: Learning the job: interaction with
Tsai&Springer (Stanford University)
Fatigue and damage of composites
First steps into textile composites
• Innovations:– Installing composites lab
– Damage detection & NDT
– Invention 2.5D and 3D-woven sandwich materials
CMG-KULeuven achievements: 1991- 2000
Research: Fibre-matrix interfaces
Experimental work on 2D/3D textilecomposites
Start of Texcomp conferences
Start of textile modelling work
Start of natural fibres research
• Innovations:– Applications of 3D-woven
sandwich panels
– Patent on 3D-knitted sandwich
– First patents on foldedhoneycombs
– Start of EUPOCO
CMG-KULeuven achievements: 2001- 2010
Research: Full expansion of meso-modelling (textile)
research
Fundamental & applied research on natural fibres
Re-focus on process & applicationdevelopment
Start of nano-engineered composites
• Innovations:– Wisetex software suite
– Patent on silk fibre composites
– Start of spin-off Econcore
– Samsonite suitcase
– Patent on bicycle helmet
– Patent on CNT sizing
PROCESSINGMACRO-
mechanicsMATERIALS
Micro-mechanics
Our approach: from constituent materials to products
A materials based view on composites…
Integrated with multiscale mechanics … towards processing and applicationdevelopment
Compositematerial
Fibrous preform (textile)
Plastics
Bio-plastics
Man-made fibres
Natural fibres
Polymer matrix
Fibre reinforcementCompositeprocessing - TS
Composite processing - TP Automotive
Aerospace
Sporting goods
Machinery
Biomedical
… leading to four focus groups in 2012
Composites on macro & meso level
Natural and bio-composites
Composites on micro&nano level
Process &applicationdevelopment
Prof. Stepan Lomov*
Dr. Aart van Vuure
Dr. Larissa Gorbatikh
Prof. Jan Ivens**
Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials
Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)
Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers
Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development
* pt ZAP
** Lessius
Hierarchy of scales: nano – µicro
Molecular dynamics: interaction CNT -polymer
CNT bending
CNT on the surface of a carbon fibre
10 µm
1 µm
100 nm
10 nm
1 nm
Hierarchy of scales: µicro – meso
100 mm
10 mm
1 mm
100 µm
10 µm FE: fibre failure
Goyal 2008
plastic zone in an impregnated yarn
FE model of 3D fabric
Hierarchy of scales: meso–Macro–Mega
1 km
100 m
10 m
1 m
100 mm FE model of a composite aeronautic part
A350 wing
Composites in constructions
Windmill blade
Composites on macro & meso level
Composites on macro & meso level
Natural and bio-composites
Composites on micro&nano level
Process &applicationdevelopment
Prof. Stepan Lomov*
Dr. Aart van Vuure
Dr. Larissa Gorbatikh
Prof. Jan Ivens**
Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials
Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)
Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers
Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development
WiseTex model for 3D angle interlock composites
WiseTex model: excellent predictions of the stiffness
1 m
Structurally stitched reinforcements
internal geometry and WiseTexmodel
correlation between damage
and stitching
sites
WiseTex worldwide
licences:industrial (6)university (30)
Composites on micro and nano level
Composites on macro & meso level
Natural and bio-composites
Composites on micro&nano level
Process &applicationdevelopment
Prof. Stepan Lomov*
Dr. Aart van Vuure
Dr. Larissa Gorbatikh
Prof. Jan Ivens**
Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials
Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)
Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers
Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development
Toughening strategies @ KU Leuven
Nano-modification of matrices, fiber/matrix interfaces, fibers
Ductile fibers(steel, CNT fibers, silk, …)
Hybridization(self-reinforced polymers, ductile fibers, …)
Intelligent use of structure(self-assembly, …)
Steel fibers
Carbon nanotube
fibers
Glass Fibers sized with CNTs
Bamboo vascular bundle, Liese 1998
0.25 wt% MWCNTs in the matrixDe Greef et al, Carbon (2011), De Greef et al, Composites Part A (2011)
• Carbon nanotubes hinder damage development in CF /epoxy composite.
Toughening composites by nano-modifications
• Position of CNTs in a composite depends on the dispersion state
Small isolated agglomerates
Network-like structure
Localization in resin rich zones
Natural and bio-composites
Composites on macro & meso level
Natural and bio-composites
Composites on micro&nano level
Process &applicationdevelopment
Prof. Stepan Lomov*
Dr. Aart van Vuure
Dr. Larissa Gorbatikh
Prof. Jan Ivens**
Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials
Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)
Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers
Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development
* pt ZAP** Lessius
Bamboo wallLiese, W., 1998
4
3
Fibres are distributeddensely in the outer regionof the wall and sparsely inthe inner region
Vascular bundleTechnical fibre
Bamboo culm Cross section
Elementary fibres
5
The elementary fibre in the bamboo wall
Bio-based Composites: bamboo fibre extraction
150
250
350
450
550
650
750
850
0 100 200 300 400 500 600
Extraction method
Stre
ngth
(MPa
)
Mechanical(rolling mill machine)
Chemical extraction(in some cases
mechanical process is required)
Steam explosion
Mechanical process(in some cases chemical process is required)
KULeuven process
Loop test
Typical stress-strain curve for treated and untreated
bamboo/epoxy composites
Strain (mm/mm)
Flex
ural
Str
ess
(MPa
)
3%
5%
0%
1%
Bamboo fibre composites
Process and application development
Composites on macro & meso level
Natural and bio-composites
Composites on micro&nano level
Process &applicationdevelopment
Prof. Stepan Lomov*
Dr. Aart van Vuure
Dr. Larissa Gorbatikh
Prof. Jan Ivens**
Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials
Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)
Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers
Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development
Application developmentof a (self-reinforced PP) composite suitcase
Characterisation of different material types
(impact, stiffness, strength, thermoformability related aspects…)
Selection of best performing one0
5
10
15
20
25
30
Silk - PBSa Curv Twintex Carbon Fibre / epoxy
30
1411
6
Rat
io o
f Abs
orbe
d en
ergy
by
pene
trat
ion
(J/m
m) a
nd d
ensi
ty
(ρ)
Fast and efficient tooling for RTM and thermoforming
• Incremental forming to produce complex metal sheet based tools (SPIF, TPIF)
• Advantages
• light-weight mold
• Heating-cooling cycle
• Multiple insert tooling
Preparation in metal plateshell
(primer - preform)
Curing (p, T)
DemoldingCured parts
Cleaning & preparationMetal shell
Injection
Productivity2 - 3 times
higher
Collaboration network in KU Leuven Association
Composites on micro&nano level
Dr. Larissa Gorbatikh
Natural and bio-composites
Dr. Aart van Vuure
Composites on macro & meso level
Prof. Stepan Lomov*
Process &applicationdevelopment
Prof. Jan Ivens**
PMAprof. VandepitteComputer Scienceprof. Roose
NDT-groupprof. Wevers
MTM-Physicsprof. SeoChemistryprof. Nies, Smet
Chemistryprof. Goderis, SmetChemical Eng.prof. VanpuyveldeBio-engineeringprof. Delcour
PMAprof. Duflou
CMG coordinators and
post-docsPhD students
Visiting andaffiliated
researchers
Technical staff (pt)
LarissaGorbatikh
IgnaasVerpoest
Stepan Lomov
Yasmine Abdin
Jan Ivens
Aart Van Vuure
Michaël Callens Manuël Adams
Marc Peeters
Bart Pelgrims
Kris Van de Staey
Aniko Lantos
Sergey Ivanov
Katleen Vallons
MarcinBarburski
Joris Baets
FaridaBensadoun
SvetlanaOrlova
Ngoc Le Quan Tran
Bart Buffel
Yentl Swolfs
Mohammadali Aravand
Niels De Greef CarlosFuentes
YasmineMosleh
Atul Jain
DieterPerremans
ValentinRomanov
OksanaShishkina
AhmadTabataba
eiEduardoTrujillo
Lina Osorio
Kelly Vanden Bosche
Bart Van Mieghem
Nhan Vo Hong Mireia Olave
Carmen TolaPerez
TomHouthoofdt
Marcel Bruijn
Frederik Desplentere
IonutDumitrascu
Jan Bens
MarjetkaConradi
MalikaKersani
ImenNasrallah
RashnalHossain
Maarten Fabré
4 senior postdocs4 junior postdocs24 PhD-students3 research enginee3 research affiliate4 visiting research4 technicians (pt)
~15 masters’ stude
CMG @ KU Leuven: a strong growth…
0
5
10
15
20
25
30
35
40
45
50
1981 1985 1990 1995 2000 2005 2010 2012
CMG-researchers
Osaka UniversityUCLA
St-Petersburg Polytechnic U
TorayHanoi UCantho U
Stanford MIT
Boeing
3Tex
… and a wide network of research collaborations
[universities and industrial partners with established long-term collaboration]
industrial university UGent
Nanocyl
HuntsmanDeceuninck SirrisUCL
Bekaert
Samsonite
Recticel
INSASnecma
Poly.Milano
EPFLRTWH
U Munich
U Valladolid
AirbusImp College
U Bristol
KTH
VolkswagenDaimler
CELC
Composites research at Ghent University
Reinforcing your composites activities!
Prof. Dr. Joris Degrieck
Who are we?
The research group “Mechanics of Materials and Structures” at Ghent University is doing research for more than 25 years on the mechanics of composite materials. The composites group is lead by Prof. Joris DEGRIECK and Prof. Wim VAN PAEPEGEM, and counts almost 20 doctoral students
Mission statement
“To study the mechanical behaviour of composite materials by a combined approach of instrumented experimental testing and adequate numerical modelling, in close collaboration with the composites industry and its suppliers”
Metals Science and Technology
• physical materials science• steel technology• durable/sustainable
materials
Mechanics of Materials and
Structures
• mechanical behaviour of materials and structures
• modeling and experimental characterization
Department of Materials Science and Engineering
Our research areas Our industrial services
Aerospace composites
Composites for wind energy
Composites for wave energy
Composites for bicycles
Crash performantcomposites
Blast proof composites
Composite joints
Next generation composites
Mechanical characterization
Dynamic testing
Inspection and monitoring
Outdoor field testing
Numerical simulation and design
Advanced finite element modelling
large-scale slamming tests at the canal in Ghent
FO3 platform (courtesy of Fred Olsen Ltd.)
filament winding simulation of
composite buoy
survivability design of composite buoys for
storm conditions
simulation of breaking wave slamming
Composites for wave energy(European FP6 project in collaboration with Dept. of Coastal Engineering and Dept. of Hydraulics (UGent),
Spiromatic, Standfast Yachts, Fred Olsen, ABB, Brevik, NTNU, Marintek, IST, Chalmers)
UGent test for bracket stiffness
UGent test for torsion stiffness
instrumented racing bicycle for field testing of comfort and
vibration levels
kinematic model of racing bicyle with applied road
accelerations
UGent all-in-one test set-up for fatigue testing of
racing bicycles
finite element simulation of the free body vibration
modes of a racing bicycle frame
Composites for bicycles(IWT R&D project; in collaboration with Museeuw Bikes and Merckx)
12
3 47
6
5
9
8
10
1 2
659
8
UGent bird impact testing facility
computer simulation of composite tube crushing
upon blast loading
high-speed imaging of drop weight impact of circular
pultruded composite tubes
Impact and crash performant composites