Diapositive 1 - SPE Automotive Division

2015
SPE ACCE - Coriolis
Composites
Abstract
CLIQUEZ POUR
MODIFIER
LE STYLE
DU TITRE
Automated Manufacturing for Mass
Production and Low-cost materials
2015 SPE ACCE - Coriolis Composites Abstract
Composites
Abstract
CLIQUEZ POUR MODIFIERCoriolis
LE STYLE
DU TITRE
Abstract
The next challenges for composites manufacturing will be to address high volume productions and very complex
parts, especially for the automotive industry.
Both machines manufacturers and simulation software editors must develop breakthrough technology: low cost
materials, scrap and mass optimization, high-volume layup machines, accurate numerical simulation of thermoforming process.
Developments for those different domains, using a strong know-how of automated fiber placement process and
aerospace industry projects, will be shown.
After showing state-of-the-art of robotic fiber placement for aerospace, a first step is to sum up main
requirements of the automotive industry: part complexity, productivity, low cost material and no scrap.
Then a technology proposal is describe : machine concept, materials to be processed, productivity and process
issues, like material capability to be processed at high speed, or preform optimization regarding impregnation or
forming issues.
Simulation issue will be illustrated by a forming topic, showing the possibility to link a fiber placement software
with some forming simulation softs.
Projects done with automotive OEM and tier 1 will conclude the presentation to illustrate the technology
developments.
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ POUR MODIFIER
LE STYLErequirements
DU TITRE
Main Automotive
2020 carbon emission regulation (EU) -> to reduce average car weight by 250kg
Technology allowing
to produce complex
contours and variable
thickness
Low cost materials:
direct roving or
heavy tow
combined with
epoxy, PU or PA
5-15 €/kg
Productivity of 1 part
per minute
Optimised fiber
orientation
low scrap
1 m2
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09
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07
06
05
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02
01
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2015 SPE ACCE - Coriolis Composites Abstract
Source: www.sgl.com
CLIQUEZ POUR MODIFIER
LE STYLE DU
TITRE
Fiber Placement
advantages
Injection and/or
forming
Fiber placement robot
1. Oriented fiber
2. Variable thickness and contours
3. No scrap
4
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ POUR MODIFIER
LE STYLE
DUconcepts
TITRE
Fiber Placement
Robot
•
3D fiber placement Robot or 2D Cartesian machine concept
•
Robot advantage: possibility to layup simplified 3D shape or 2D blanks
•
Production of 2D flat blanks ready to be stamped or formed and injected
•
Use of many fibers at time to achieve requested productivity
•
Optimized footprint area
•
Compact machine, easy to set up within 1 week
5
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ
POUR MODIFIER
LE the
STYLE
DU
TITRE
Mult-imaterial
capability with
same
AFP
robot
Fiber placement machine & robot to produce 2D to 3D
preforms with very low scrap
AUTOMATED DRY FIBER PLACEMENT
•
Use of low cost dry heavy tow with binder : 50K carbon or glass direct roving
•
Optimization of the preform to reduce injection time
•
Low fiber cost compare to fabrics
•
No more cutting table and waste management!
AUTOMATED THERMOPLASTIC FIBER PLACEMENT
•
Use of low cost thermoplastic towpreg based on 50K
•
Complex preform ready to be stamped
•
Quasi in-situ consolidation
•
Can be combined with thermoplastic over molding
AUTOMATED THERMOSET FIBER PLACEMENT
6
•
Use of low cost out of autoclave thermoset material
•
Complex preform ready to be stamped and formed
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZProductivity
POUR MODIFIER
DU TITRE
issue forLE
lat STYLE
fiber placed
blanks
III - AFP readinessProductivity
regardingincreased
Automotive
Industry
vs number of
parts
40.00
Productivity (kg/h)
35.00
30.00
20, 28.60
25.00
40, 33.91
30, 31.95
10, 21.77
20.00
15.00
10.00
1, 6.77
5.00
0.00
0
10
20
30
Number of parts
•
Maximize deposition rate by laying many parts per ply
•
Cutting and adding fibers on the fly without slowing down
the machine
•
Low tension maintain material integrity even at high speed
•
Fiber stiffness and cohesion to prevent bulking & shearing
of the preform during fast layup, even for thick laminates
or curved paths
7
2015 SPE ACCE - Coriolis Composites Abstract
40
50
CLIQUEZ
POUR
MODIFIER
LE 3D
STYLE
DU TITRE
Local
reinforcement
with
continuous
fiber
•
•
•
•
8
Placement of local 3D
continuous reinforcement
can be combined with
isotropic structure
Placement can be done with
random dry preform (TTE)
Or with thermoplastic
overmoulding
Few fibers can increase
significantly the part
stiffness, with very low
material and process costs
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ POUR
MODIFIER
LE STYLE
DU TITRE
Draping
and Infusion
– AFP optimisation
•
Reduced permeability of dry AFP UD tapes (10 – 20x lower then
NCF)
→ possible solution: geometric approach by including gaps to
improve permeability
•
AFP Flow Channels
Integrity of AFP preforms at conventional draping
 optimization of process control and fiber orientation
to improve formability
 scrap optimization of the blanks
AUDI A1 – ¼ Roof 100% AFP
Coriolis Drape Testbench - PRESCHE
 Drape targeted AFP layup
Local fibre deviation
9
Drape Simulation
– 45° Corner
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ
POUR
MODIFIER
LE STYLE
DUbehavior
TITRE
Study of
unidirectional
material
draping
Phase 1: study of unidirectional material behavior (numerical simulation & experimental testing) with basic
shapes
Hemisphere tooling, Wide UD tape and slit tows material.
Double-corner shape.
CADFIBER AFP simulation software interfaced with ESI Pamform and Aniform
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ
POUR
MODIFIER
LE STYLE
DUbehavior
TITRE
Study of
unidirectional
material
draping
Phase 2: study of UD material behavior (numerical simulation & experimental) with complex shapes
Z frame partially stamped, prepreg thermoset material
CADFIBER AFP simulation software interfaced with ESI Pamform and Aniform
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ
POUR
MODIFIER
LE STYLEwith
DUPartners
TITRE
V - Coriolis
Software:
Full simulation
Automotive B-Pillar case study
Infusion / RTM process
simulation
Structural analysis: Stress/failure, crash,
fatigue, curing/distortion
Curing/distortion
Forming process simulation: fiber
orientation and wrinkling
prediction
Composites Design /
ply book
Drapability analysis and ply
boundary cuts preparation
CADFIBER Fiber placement process
simulation: Tape courses and tows
generation
Coriolis CADFiber Software:
Development of full process
simulation chain (with Partners)
12
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ POUR MODIFIER LEAutomotive
STYLE DU projects
TITRE
•
•
•
•
•
•
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PRESCHE: AUDI project founded by Karlsruher Institute for Technology: automated production of
composite structures
DEMOS: FAURECIA - Vehicule du futur – Ademe–– composite seats
3DMAT: ESI Group & PSA – process simulation for high volume production
DYNAFIB: COOPER STANDARD production of thermoplastic injected part with overmolded 3D local
reinforcement
TPRC: thermoplastic fiber placement, consolidation, forming and simulation
FIABILIN: flax and bio sourced matrix – Arkema
2015 SPE ACCE - Coriolis Composites Abstract
STATE
OF THEPOUR
ART - AEROSPACE
CLIQUEZ
MODIFIERPROGRAM
LE STYLEREFERENCES
DU TITRE
AIRBUS A320neo
AIRBUS A350 XWB
AIRBUS DS Ariane
DASSAULT AVIATION Falcon 5X
BOMBARDIER CSeries*
IRKOUT MS21
14
*Trademark of Bombardier Inc. or its subsidiaries
Images provided courtesy of Bombardier Inc. and Dassault Aviation
2015 SPE ACCE - Coriolis Composites Abstract
CLIQUEZ POUR MODIFIER LE STYLE DUCONTACT
TITRE
ZA du Mourillon
Rue Condorcet
F-56530 QUEVEN
Phone: +33 (0)2 97 59 94 98
Fax: +33 (0)2 97 59 90 24
Commercial
M. Davy Leboucher
Mobile: +33 (0)6 01 24 22 47
[email protected]
Technical
M. Alexandre Hamlyn
Mobile: +33 (0)6 72 95 87 18
[email protected]
2015 SPE ACCE - Coriolis Composites Abstract