Embed Size (px)
Citation preview
RWTH, Peter Winandy
Textile Production Technologies for Multi-Material-Lightweight Components JEC World 2017 Conference - Production Technology for Multi-Material
Lightweight Components - Hans-Christian Früh
2
Textile Production Technologies for Multi-Material-Lightweight Components
Outline
• Motivation
• Tailored Textiles the enabler of multimaterial designs
Tailored NCF
Open Reed Weaving
• Insert Integration using Laser Cutting
• Z-reinforcement with textile joining processes
• Multimaterial Joints
• Conclusion
3
Motivation
Considering multimaterial approach in early steps of composite
process chains
• Increasing potential of light weight design and reduced production costs
• Modification of existing design and manufacturing route of multimaterial FRP parts
Textile
Production Drilling ´S
tate
of th
e
art
Tailored NCF
Production
Consoli-
dation
New
Preforming + Fastener
Integration
Preforming
Rework
Consoli-
dation
Fastener
Adhesive Rework
4
Tailored Textiles - the enabler of multimaterial designs
• Approach: application of Tailored Textiles
Local adaption of textile properties
Reinforcements
- Fiber orientation
- Fiber amount
Insert or joint preparation of reinforcement textile
Drapeability
Near-net-shape
• Based on conventional textile production processes
High process speeds
High maturity level
Application of Tailored Textiles
Tailored NCF [ITA]
Open Reed Weaving [ITA]
5
Tailored Textiles – the enabler of multi material composite structures
Tailored NCF
• Local reinforcements
• Adressing joint or insert loads
• Adjusting warp knitting pattern as
• Process aid
[SGL]
[BMW]
[ITA/KCTECH]
ITA and KCTECH
6
Tailored textiles – the enabler of multi material composite structures
Local reinforced woven textiles
Feed of additional fibres only in certain
needle areas
Possibility of local reinforcements with
additional fibre system
Fabric pattern right side:
Basic pattern: carbon fibre, 800 tex
reinforcement: carbon fibre, 800 tex
Feeding of up to 50 individual threads
(carbon, 800 tex) in a multiaxial system
Basic weave Local reinforcement
7
Improvement in material efficiency through tailored fabrics
• Experimental evaluation of potential for local reinforcements
Different load cases
Varying reinforcement geometry
Comparison to different references
Reinforcement along the load path of the multimaterial component
8
Fasteners for Multi Material Design applications
Integration of fasteners
Fasteners
Combination of
different materials
Substitution of commercial
components by composite parts
Detachable and
standardized joints
10 mm [ITA]
[ITA]
[ITA]
[ITA]
9
Innovative LaserInsert-approach
Ultra precise laser cutting of carbon fibre stacks
Laser source Ultra-short pulsed
Laser
Insert
Integration
Preform
Consolidation
10 mm
LUNOVU
System integration
Amphos
ultra-short pulsed
Laser source
ITA
Preforming process
Kohlhage Fasteners
Innovative
fasteners/inserts
Schmalz
Handling device
ILT
Laser processing
Laser source
Insert
Preform
Fixation unit
10
Innovative LaserInsert-approach
Results
• Reduced process times -> no drilling, adhesive preparation and application
• Higher part performance -> Increased pull-out forces for fasteners
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000P
ull
-ou
t fo
rce
[N
]
"Big Head"Aufgeklebt
"Big Head"integriert
"Kim"eingeklebt
InnovativerInsert
Variations
La
se
rInsert
Onsert
Integration
under one layer
Drilling and paste
Innovative process with
laser processing
Be
nc
hm
ark
11
Improvement in mechanical properties by tufting
Tufting in the production of sandwich panels
Robot
Tufting unit
Thread supply
Presser foot
Tufting needle
Thread
Tufting seam Textile
Insert
Sandwich Core
Top Layer Tufting Thread
Increase in z-Axis properties (local reinforcement)
Fixation of the Insert on-top of the textile or on the sandwich
core
Increase in insert-in-plane and out-of-plane mechanical
properties
Up to 1000 Stiches per Minute
12
Joining using textile positive locking
Metal
FRC
Adhesive bonding
Form-fit joint
„Additional safety“
New shear connectors
No fibre damage / ductile cracking
New shear connectors
Surface modification of metal
Small metal spines added
Afterwards textile production technologies
such as RTM
No damage to textile structure
Ductile cracking
Hybrid joint: New shear connectors
13
Increasing mechanical performances
Joining – multimaterial joints
1 mm
Hybrid joint: New shear connectors
Three shear connector designs: cylindric, pointed, round
Surface modification of metal
Shear connectors produced by welding process
Shear stress capacity of 1 kN per connector
For various metals: titanium, steel, aluminium
Different geometries
In combination with composites
Increased stability
Force transmission to inner layers
Ductile post-cracking behavior
High energy absorption
Easy manufacturing process
14
Joining – properties of new multimaterial joints
Higher maximum load
New multi stage breakdown
Triple crash energy absorption
Displacement [mm]
Forc
e [N
]
6 connectors
2 connectors
No connectors
15
Improvement in preforming efficiency through tailored fabrics
Modification of existing design and manufacturing route of FRP parts
Technology pre-selection
and preliminary design 1
Production oriented
conceptual part design 2
Concept development based
on tailored textiles
I Requirement elicitation,
definition of goals
II Conceptual part design
IV Detailed laminate design
Conventional product
development process
III Preliminary laminate
design
V Production planning
Detailed reinforcement
design 3
Tailored textiles based
subpreform concept
Economic and technical
evaluation 4
16
Conclusion
Textile production steps are the enabler for high performance multi
material components
Textile
Production Drilling ´S
tate
of th
e
art
Tailored NCF
Production
Consoli-
dation
New
Preforming + Fastener
Integration
Prefroming
Rework
Consoli-
dation
Fastener
Adhesive Rework
• Considering Tailored Textiles based concepts
• Enabling cost effective lightweight components
• Based on conventional textile production processes
High process speeds
High maturity level, robust manufacturing processes
Thank you for your kind attention! Our Partners:
ITA TechnologieTransfer GmbH, Aachen
Institut für Textiltechnik Augsburg gGmbH, Augsburg
ITA Teknoloji Transfer Ltd. Sti., Bursa (Türkei)
Dipl.-Ing. Hans-Christian Früh
Composites Division
Institut für Textiltechnik der RWTH Aachen University
Tel.: +49/(0)241/80 23 272
