Intrinsic Hybrid Composites for Lightweight Structures: New Process Chain Approaches

2016 ◽  
Vol 1140 ◽  
pp. 239-246 ◽  
Author(s):  
Simon Frederik Koch ◽  
Daniel Barfuss ◽  
Mathias Bobbert ◽  
Lukas Groß ◽  
Raik Grützner ◽  
...  
Keyword(s):  
Hybrid Composites ◽  
Process Chain ◽  
Lightweight Structures ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Steel Sheets ◽  
Process Chains ◽  
New Process ◽  
Hybrid Laminates ◽  
Automated Fiber Placement

This publication describes new process chain approaches for the manufacturing of intrinsic hybrid composites for lightweight structures. The introduced process chains show a variety of different part and sample types, like insert technology for fastening of hollow hybrid shafts and profiles. Another field of research are hybrid laminates with different layers of carbon fiber reinforced plastics stacked with aluminum or steel sheets. The derived process chains base on automated fiber placement, resin transfer molding, deep drawing, rotational molding and integral tube blow molding.

scholarly journals A Modelling Approach for the Manufacturing Process Chain of Composite Lightweight Structures

2008 ◽  
Vol 43 ◽  
pp. 157-166
Author(s):  
Michael F. Zaeh ◽  
Mirko Langhorst
Keyword(s):  
Automotive Industry ◽  
Process Design ◽  
Process Chain ◽  
Lightweight Structures ◽  
Process Chains ◽  
High Residual Stress ◽  
Manufacturing Techniques ◽  
Manufacturing Process Chain ◽  
Related Process ◽  
Modelling Approach

In order to support production tasks in the automotive industry, to reduce costs due to a trial and error procedure during process design and plant construction and to secure the accuracy of frame component assemblies, modern simulation methods are applied. In production chains a row of different manufacturing techniques are established. To accompany the number of manufacturing steps with the aid of calculation methods, an interacting of each simulation with the preliminary one is necessary. Such process chains help to determine the structural properties and geometrical accuracy of components and assemblies during manufacturing of composite lightweight structures and ensure their final quality. The basic difficulty of handling aluminium composites with steel reinforcements is the high residual stress level in the reinforcing elements and the adjoining matrix. This stress state can have a significant effect on the desired machining results and the related process itself. Contemplating this reveals the importance of defining a process chain by simulation.

scholarly journals A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

2018 ◽  
Vol 2 (3) ◽  
pp. 42 ◽  
Author(s):  
Mohammad Rakhshbahar ◽  
Michael Sinapius
Keyword(s):  
Mechanical Properties ◽  
Composite Structures ◽  
Fiber Composite ◽  
Gap Effect ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Novel Approach ◽  
Automated Fiber Placement ◽  
Automated Processing ◽  
Processing Techniques

Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.

scholarly journals In Situ Consolidation of Thermoplastic Prepreg by Generating Harmonic Oscillations on the Consolidation Roller

2021 ◽  
Vol 6 (1) ◽  
pp. 1
Author(s):  
Mohammad Bahar ◽  
Marco Brysch ◽  
Michael Sinapius
Keyword(s):  
Contact Time ◽  
Compressive Force ◽  
Harmonic Oscillations ◽  
Fiber Placement ◽  
Specific Strength ◽  
Reinforced Plastics ◽  
Short Contact Time ◽  
Current State ◽  
Automated Fiber Placement ◽  
Strength And Stiffness

Automation technologies such as Automated Fiber Placement (AFP) or Automated Tape Laying (ATL) are widely used in the aerospace industry today. However, these processes can still be further improved for higher productivity. Fiber-reinforced plastics allow the production of components with extremely high specific strength and stiffness. Regarding the automated manufacturing processes, the thermoplastic tape placement offers efficiency improvements compared to the nowadays more commonly used thermoset tape placement, especially through the substitution of the expensive and time-consuming autoclave process. The consolidation of thermoplastic Prepregs is achieved with an elastic or rigid roller according to the current state of the art. The Prepregs must be consolidated precisely on the substrate or on top of each other. The most important process parameters for high-quality laminate structure with low porosity are the control of heat source, consolidation force, consolidation roll speed, and tape tension. The efficiency of the AFP process can generally be improved by increasing the speed of the consolidation roller. By increasing the speed of the consolidation roller, porosity is increased and mechanical properties of the laminate are reduced significantly due to the short contact time between consolidation roller and Prepregs. This study investigates a process that can reduce these challenges by increasing the contact time and force duration of the consolidation roller on the Prepregs. The consolidation roller in this study is additionally to be driven by the harmonic oscillations. The new method allows the consolidation roller to oscillate forward and backward during the fiber placement process. This creates another force vector in addition to the compressive force of the consolidation roller and increases the bonding strength between the layers.

scholarly journals Design for Composites: Derivation of Manufacturable Geometries for Unidirectional Tape Laying

2019 ◽  
Vol 1 (1) ◽  
pp. 2687-2696
Author(s):  
Harald Voelkl ◽  
Andreas Kießkalt ◽  
Sandro Wartzack
Keyword(s):  
Strength Properties ◽  
Efficient Production ◽  
Specific Energy Absorption ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Laminate Design ◽  
Automated Fiber Placement ◽  
Production Techniques ◽  
High Specific Energy ◽  
Design Freedom

AbstractEven though providing excellent specific stiffness and strength properties, high specific energy absorption and a great degree of design freedom, fibre-reinforced plastics still have to make their way into higher volume applications. Addressing the manufacturing challenges, particularly efficient production techniques are Automated Tape Laying (ATL) and Automated Fiber Placement (AFP), as pointed out by various studies and use cases. However, current Computer Aided Engineering approaches for optimised laminate design still lack the capability to produce results suitable for ATL/AFP. A new method for deriving tape courses from any finite element laminate optimisation result is presented and applied to a virtual demonstrator. An outlook is given on further necessities of extending current laminate optimisation approaches.

Prozesskette zur Herstellung textiler 3D-Preforms/Multi-step production of textile 3D preforms - Use of tufting and particle foam technology for draping textile semi-finished parts

2017 ◽  
Vol 107 (06) ◽  
pp. 392-398
Author(s):  
S. Schöfer ◽  
M. Schmitz ◽  
T. Prof. Gries ◽  
C. Mack ◽  
A. Basler
Keyword(s):  
Automated Manufacturing ◽  
Process Chain ◽  
Processing Times ◽  
Forming Technology ◽  
Kleine Und Mittlere Unternehmen ◽  
Process Chains ◽  
New Process ◽  
High Investment ◽  
Batch Sizes ◽  
Stamp Forming

Die Umsetzung von Prozessketten zur automatisierten Fertigung von 3D-Preforms im industriell etablierten Stempelumformverfahren ist aufgrund hoher Investitionskosten für kleine und mittlere Unternehmen bisher nicht wirtschaftlich tragbar. Die neuentwickelte Prozesskette wirkt dem entgegen und verspricht, komplexe 3D-Preforms bei geringer Prozesszeit sowohl textil- als auch lastgerecht herzustellen und dabei Ausschussquoten aufgrund von Drapierfehlern sowie den Verschnitt zu senken.   Implementing process chains for the automated manufacturing of 3D textile preforms based on the established industrial stamp forming technology is not economical for small- and medium-sized enterprises due to high investment costs for small batch sizes and variable geometries. The new process chain counteracts by manufacturing complex 3D preforms at low processing times, both textile- and load-conform, while reducing scrap rates from draping errors and offcut.

Automated Fiber Placement of Composite Wind Tunnel Blades: Process Planning and Manufacturing

2019 ◽  
Author(s):  
Ramy Harik ◽  
Joshua Halbritter ◽  
Dawn Jegley ◽  
Ray Grenoble ◽  
Brian Mason
Keyword(s):  
Wind Tunnel ◽  
Process Planning ◽  
Fiber Placement ◽  
Automated Fiber Placement

scholarly journals Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1951
Author(s):  
Yi Di Boon ◽  
Sunil Chandrakant Joshi ◽  
Somen Kumar Bhudolia
Keyword(s):  
Processing Parameters ◽  
Filament Winding ◽  
Reference Points ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Fiber Placement ◽  
Automated Fiber Placement

Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

Effect of gap on strengths of automated fiber placement manufactured laminates

2021 ◽  
Vol 263 ◽  
pp. 113677
Author(s):  
Hiroshi Suemasu ◽  
Yuichiro Aoki ◽  
Sunao Sugimoto ◽  
Toshiya Nakamura
Keyword(s):  
Fiber Placement ◽  
Automated Fiber Placement
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