Diapositive 1 - SPE Automotive Division
Transcription
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 10 09 08 07 06 05 04 03 02 01 3 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 • • • • • • 13 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