Systematic Process Chain Creation for CFRP Structures in Early Product Development Stages

A planning method is presented which allows to systematically building process chains based on a preliminary design of composite structures. The method utilises the specific sequences of procedural steps that occur in the production of carbon fibre reinforced plastic (CFRP) structures, to build sub process chains for each component of the structure. Process restrictions are considered to evaluate the suitability of different production processes. To obtain the whole process chain of the structure, different joining methods are applied in addition to combine the components and its sub process chains. The results of the presented method are used in an overarching development procedure to investigate resulting impacts on the solution. Possible impacts could be the production costs or the material characteristics.

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Heuristic-Based Evaluation of Energy Flows in Press Hardening Process Chains

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.473.816 ◽

2011 ◽

Vol 473 ◽

pp. 816-823 ◽

Cited By ~ 1

Author(s):

Reimund Neugebauer ◽

Frank Schieck ◽

Angela Göschel ◽

Julia Schönherr

Keyword(s):

Qualitative Evaluation ◽

Resource Efficiency ◽

Process Chain ◽

Press Hardening ◽

Whole Process ◽

Quantitative Calculation ◽

Hardening Process ◽

Energy Flows ◽

Process Chains ◽

The Press

Energy and resource efficiency is a pressing issue for technological markets in the 21st century. In the field of production technology the development of energy and resource efficient processes and process chains is of particular importance. In order to meet these needs sustainable methods and standards have to be developed. This paper presents a new procedure to calculate and evaluate the energy and resource efficiency of process chains. The method consists of 4 stages that proceed from the real world to the quantitative calculation and qualitative evaluation of material and energy flows. The method is explained and validated using press hardening process chains as an example. The procedure enables the user to systematically capture and structure the press hardening process chain and subsequently develop a comprehensive model of the whole process chain. As a result, it allows to calculate the energy requirements for each stage of the process chain, and later on the process chain as a whole. The intention of the developed procedure is to provide a tool to detect the most energy efficient variant from a range of possible process chains.

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Methods for the Control of Uncertainty in Multilevel Process Chains Using the Example of Drilling/Reaming

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.104.103 ◽

2011 ◽

Vol 104 ◽

pp. 103-113 ◽

Cited By ~ 1

Author(s):

Michael Haydn ◽

Thomas Hauer ◽

Eberhard Abele

Keyword(s):

Systematic Approach ◽

Simulation Models ◽

Production Costs ◽

Material Strength ◽

Process Chain ◽

Production Processes ◽

Process Chains ◽

Key Aspects ◽

And Control ◽

Previous Step

Uncertainty during production processes has an important influence on the product quality as well as production costs. For multilevel process chains with serially connected processes, additional uncertainty can be caused by the previous step. The manufacturing of precision holes by drilling and reaming is an important multilevel process chain. The interactions between machine, tool and pre-drilled hole cause process errors during the quality determinant final reaming process. In this paper, a systematic approach for the identification and control of uncertainty during the reaming process is presented. Thus, the influence of key aspects like skewness of pre-drilled hole or the influences of material strength gradients are analyzed. Further, simulation models for the consideration of these uncertainties are presented.

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Mode I fracture toughness of CFRP as a function of temperature and strain rate

Journal of Composite Materials ◽

10.1177/0021998316682309 ◽

2016 ◽

Vol 51 (23) ◽

pp. 3315-3326 ◽

Cited By ~ 21

Author(s):

JJM Machado ◽

EAS Marques ◽

RDSG Campilho ◽

Lucas FM da Silva

Keyword(s):

Strain Rate ◽

Automotive Industry ◽

Composite Structures ◽

Numerical Study ◽

Mode I ◽

Strain Rates ◽

Mode I Fracture Toughness ◽

Reinforced Plastic ◽

Carbon Fibre Reinforced Plastic ◽

The Impact

Composite structures currently used in the automotive industry must meet strict requirements for safety reasons. They need to maintain strength under varied temperatures and strain rates, including impact. It is therefore critical to fully understand the impact behaviour of composites. This work presents experimental results regarding the influence of a range of temperature and strain rates on the fracture energy in mode I, GIC, of carbon fibre reinforced plastic plates. To determine GIC as a function of temperature and strain rate, double cantilever beam specimens were tested at 20, 80 and −30℃, with strain rates of 0.2 and 11 s−1. A complementary numerical study was performed with the aim of predicting strength using the measured values. This work has demonstrated a significant influence of the strain rate and temperature on GIC of the composite materials, with higher strain rates and lower temperatures causing a decrease in the GIC values.

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Non-Destructive Dielectric Assessment of Water Permeation in Composite Structures

MRS Proceedings ◽

10.1557/proc-591-105 ◽

1999 ◽

Vol 591 ◽

Author(s):

P. Boinard ◽

E. Boinard ◽

R.A. Pethrick ◽

W.M. Banks ◽

R.L. Crane

Keyword(s):

Time Domain ◽

Dielectric Spectroscopy ◽

High Frequency ◽

Composite Structures ◽

Frequency Domain Analysis ◽

Adhesively Bonded ◽

Water Permeation ◽

Reinforced Plastic ◽

Carbon Fibre Reinforced Plastic ◽

Non Destructive

ABSTRACTOver the last ten years, the application of high frequency dielectric spectroscopy techniques for the assessment of composite structures has been investigated. Novel approaches to assess non-destructively the evolution during ageing of adhesively bonded carbon fibre reinforced plastic (CFRP) structures and bulk glass fibre reinforced plastic (GRP) structures are presented in this paper and the results are critically assessed.The applicability and limitations of dielectric measurements, in both frequency and time domain, to the monitoring of water ingress at 30°C and 60°C are examined. The correlation between gravimetric and high frequency dielectric spectroscopy data demonstrates the suitability of the techniques regarding the assessment of water uptake in composites structures and illustrates its potential as a non-destructive evaluation (NDE) technique. The dielectric time domain response (TDR) study of adhesively bonded structures indicates a new way to assess such structures. The approach for frequency domain analysis of bulk GRP using a coaxial probe technique indicates the potential portability of the technique for in-situ measurements.

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Effect of moisture on elastic and viscoelastic properties of epoxy and epoxy-based carbon fibre reinforced plastic filled with multiwall carbon nanotubes

Composites Part A Applied Science and Manufacturing ◽

10.1016/j.compositesa.2016.08.026 ◽

2016 ◽

Vol 90 ◽

pp. 522-527 ◽

Cited By ~ 10

Author(s):

Tatiana Glaskova-Kuzmina ◽

Andrey Aniskevich ◽

Alfonso Martone ◽

Michele Giordano ◽

Mauro Zarrelli

Keyword(s):

Carbon Nanotubes ◽

Carbon Fibre ◽

Viscoelastic Properties ◽

Multiwall Carbon Nanotubes ◽

Reinforced Plastic ◽

Effect Of Moisture ◽

Carbon Fibre Reinforced Plastic ◽

Multiwall Carbon

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Machine learning and simulation-based surrogate modeling for improved process chain operation

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-07084-5 ◽

2021 ◽

Author(s):

André Hürkamp ◽

Sebastian Gellrich ◽

Antal Dér ◽

Christoph Herrmann ◽

Klaus Dröder ◽

...

Keyword(s):

Surrogate Modeling ◽

Temperature History ◽

Injection Molding Process ◽

Process Chain ◽

Molding Process ◽

Whole Process ◽

Virtual Production ◽

Sensor Model ◽

Fast Prediction ◽

Operation Phase

AbstractIn this contribution, a concept is presented that combines different simulation paradigms during the engineering phase. These methods are transferred into the operation phase by the use of data-based surrogates. As an virtual production scenario, the process combination of thermoforming continuous fiber-reinforced thermoplastic sheets and injection overmolding of thermoplastic polymers is investigated. Since this process is very sensitive regarding the temperature, the volatile transfer time is considered in a dynamic process chain control. Based on numerical analyses of the injection molding process, a surrogate model is developed. It enables a fast prediction of the product quality based on the temperature history. The physical model is transferred to an agent-based process chain simulation identifying lead time, bottle necks and quality rates taking into account the whole process chain. In the second step of surrogate modeling, a feasible soft sensor model is derived for quality control over the process chain during the operation stage. For this specific uses case, the production rejection can be reduced by 12% compared to conventional static approaches.

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Analysis and Design of a Leading Edge with Morphing Capabilities for the Wing of a Regional Aircraft—Gapless Chord- and Camber-Increase for High-Lift Performance

Applied Sciences ◽

10.3390/app11062752 ◽

2021 ◽

Vol 11 (6) ◽

pp. 2752

Author(s):

Conchin Contell Asins ◽

Volker Landersheim ◽

Dominik Laveuve ◽

Seiji Adachi ◽

Michael May ◽

...

Keyword(s):

Leading Edge ◽

Bird Strike ◽

High Lift ◽

Analysis And Design ◽

Actuation System ◽

Aerodynamic Properties ◽

Reinforced Plastic ◽

Stall Angle ◽

Carbon Fibre Reinforced Plastic ◽

Electromechanical Actuation

In order to contribute to achieving noise and emission reduction goals, Fraunhofer and Airbus deal with the development of a morphing leading edge (MLE) as a high lift device for aircraft. Within the European research program “Clean Sky 2”, a morphing leading edge with gapless chord- and camber-increase for high-lift performance was developed. The MLE is able to morph into two different aerofoils—one for cruise and one for take-off/landing, the latter increasing lift and stall angle over the former. The shape flexibility is realised by a carbon fibre reinforced plastic (CFRP) skin optimised for bending and a sliding contact at the bottom. The material is selected in terms of type, thickness, and lay-up including ply-wise fibre orientation based on numerical simulation and material tests. The MLE is driven by an internal electromechanical actuation system. Load introduction into the skin is realised by span-wise stringers, which require specific stiffness and thermal expansion properties for this task. To avoid the penetration of a bird into the front spar of the wing in case of bird strike, a bird strike protection structure is proposed and analysed. In this paper, the designed MLE including aerodynamic properties, composite skin structure, actuation system, and bird strike behaviour is described and analysed.

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