Manufacturing

Transcription

Manufacturing

Endlosfaser verstärkte Thermoplastmaterialien als
Alternative in Hochleistungs-Leichtbaustrukturen
Werkstoff Kolloquium 2006
Dr.-Ing. Wolfgang Dudenhausen
DLR – Institut für Bauweisen- und Konstruktionsforschung (IBK), Stuttgart
Köln, 5. Dezember 2006
Folie 1 Werkstoff Kolloquium 2006 W. Dudenhausen
27 .1 1.20 06
Content
•
Department of Computer Supported Component Design
•
Vacuum consolidation technique as basis for manufacturing
large flat structures
•
Vacuum moulding - a shaping process for complex geometry
•
Application examples
•
Further Application and Future prospects
•
Conclusion
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DLR Locations
31 research institutes and
scientific/technical facilities at
8 sites
4 branches
German-Dutch Wind Tunnel DNW)
European Transonic Wind Tunnel ETW)
Institute of Structures and Design, DLR - Stuttgart
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Computer Supported Component Design
Head of Department:
Dr.-Ing. Wolfgang Dudenhausen
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Polymer
Technology as
Basis of
Structural
Design
Mechanical Finishing e.g. with
Jetcut or Machine Tools
Tempering
Si-Infiltration (LSI)
Pyrolysis
Polymer CFRP Structure
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Competence
Design and Engineering
Evaluation and design
Development of new and innovative
high performance structures
Mission depending design (UCAV)
CAD/CIM
FE/MKS
Tool- and Manufacturing
Development
Technology for manufacturing with
thermoplastics and infusions processes
Joining technique and tooling concepts
Integrated QS
Transfer of Technology
Provision of specified process
sequences,
Design for manufacturing
Consulting of internal and external
partners.
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Benefits of Thermoplastic Composites
Processing and Fabrication:
•Rapid fabrication
•No chemistry during processing
•Manufacture complex parts in a single step
•Integrated fabrication and assembly
Properties: (high performance thermoplastic composites)
•High toughness and damage tolerance
•Excellent solvent resistance and very low moisture absorption
•Excellent high temperature properties
•Outstanding fire resistance and very low smoke generation
•Superior wear resistance
Drawbacks:
General:
High manufacturing temperature
•Indefinite shelf life
Upper material cost than thermoset
•Room temperature storage
Lower Tg than thermoset
•Recyclable
Source: Airbus Deutschland GmbH
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Overview of Thermoplastic Polymer Matrices
PPS: Poly Phenylen Sulphide
PEI:
Poly Ether Imide
PEEK: Poly Ether Ether Ketone
PEKK: Poly Ether Ketone Ketone
Matrix
Tg
(°C)
Typical Process
Temperature (°C)
Comments
PPS
90
325
Excellent environmental resistance
Low Tg
Micro cracking
PEI
217
330
High Tg
Environmental resistance
PEEK
143
390
Extensive database
High toughness
High process temperature
PEKK
156
340
Limited database in composite form
High toughness
Lower process temperature than PEEK
Source: Cytec Engineered Materials
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Comparison of Material Cost
Reference: Flat Plate 1 m², 3 mm Thickness
Source: Institute of Structures and Design, DLR 2003
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Fibre Reinforced Thermoplastics Manufacturing
Technologies
Pressure
Vacuum
Heating /
cooling
Autoclave
Heated Press
Atmospheric pressure
Prepreg
Pressure roller
Vacuum
Insulation
Heated Table
Vacuum table
Heated table
Hand or robot lay up
Folie 10 Werkstoff Kolloquium 2006 W. Dudenhaus en
27 .1 1.20 06
Fibre Reinforced Thermoplastics Manufacturing
Technologies
A
Limited area
over 1 Mio. €
A
Limited area
over 1 Mio. €
A
Extendable area
under 200.000 €
A
Extendable area
over 1 Mio. €
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Content
Conclusion
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Vacuum Consolidation Techniques
General Characteristics:
•
Low investment cost
•
Adaptable work space through
modular set-up
•
Simple shaped plates can be
consolidated on heated table using
vacuum down to 3 mbar
•
Low porosity reachable (< 2%)
Atmospheric pressure
Vacuum
Insulation
Vacuum table
Heated Table
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Vacuum Consolidation Technique
Realization of tailored
panels
Pre cut with water jet
Fixing of prepreg layers
with a soldering gun
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Principle of vacuum consolidation
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Main characteristics of IBK/DLR vacuum table facility
• Processing temperature up to
400° C is possible
• Active cooling system is
integrated in the table, usable
media: gas and fluids
• Vacuum channels are
integrated in the table surface
• Main dimensions of the table
– at present:
3000 mm x 1200 mm
Manufacturing of simple shaped rib
stiffened plates is possible
– in near future:
4800 mm x 1200 mm
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Content
Conclusion
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Vacuum Molding as a Shaping Process
Pre consolidated plate
• Basis for shaping
process is a vacuum
consolidated plate
• Vacuum table can be
completed by a
positive mold
• Heating of the mold
can be realized by the
heated table itself; in
case of unfavorable
mold dimensions
additional heating is
necessary
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• Mold and plate are
covered with a
vacuum bag
• Kapton vacuum bag
consists of two foil
parts glued together
• Additional heater mat
assures constant
temperature within
the CFRP plate
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• Due to manufacturing a
spring in angel has to
be taken into account
• Inner and outer surface
have good quality
ca. 1000 mm
• C-Scan showed no
significant failure in the
shell
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Content
Thermoplastic CF-PEEK rudder
Hybrid Fan Blade
Conclusion
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Rudder with Fibre Reinforced Thermoplastics
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Vacuum Consolidation Techniques
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Vacuum Welding Method
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Vacuum Welding Method
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Press Welding Method (Rib forming)
Welding device
4
6
1
2
7
1. rudder skin
2. L-Stringer
3. rib to be welded
4. compressor part
3
2
4
5
8
5. spring washer set
6. bracket
7. heating element
8. insulating material
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Bonding Techniques
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Press Welding Method (Spar)
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Comparison of Manufacturing Cost
Rudder with Thermosetting or Thermoplastic Prepregs
(APC 2)
Calculated by EADS
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Content
Thermoplastic CF-PEEK rudder
Hybrid Fan Blade
Conclusion
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Basic Concept
Joining Area
Hybrid fan blade
for NDV 4.5
CFRP
Reduction of structural weight
Titanium
Hybrid fan blade for BR700
engine family
Resistance against erosion and FOD
by having a metal leading edge
Reduced rotational blade energy with
view on a fan blade off
Increasing structural damping
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Results of FE Modelling
Different FE models showed good
correspondence with respect to
equivalent stress (v. Mises)
HEX meshed blade
Combined HEX /
SHELL mesh
FE analysis showed reduction
of stress within the Titanium
part and an acceptable
utilisation of CFRP material
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Realised Compressor Blades
Development status
• Experimental
verification of joining
technique and
assessment of load
carrying capacity
• Preparation of FE
modelling technique for
hybrid structures
• Demonstration of an
material appropriate
manufacturing
technique
Hybrid fan blade for NDV
Hybrid fan blade for BR700
engines
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Content
Conclusion
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Generic Target Structure - Leading Edge
Leading edge made of
thermoplastic CF-PEEK
Outer shell
Typical leading edges:
Rib
• Wing
• Horizontal stabilizer
• Vertical stabilizer
Rib flange
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Combination of Short and Continuous Fiber
Reinforced Composites
Different link systems between a rib and an outer shell
Outer shell
Rib
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Principle of over injection molding
T-Pull specimen for
verification of rib flange
Injection of short
fiber reinforced CFPEEK
Embedded
continuous fiber
reinforced material
Transfer of
experience
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Main intention of over injection molding for rib flanges:
•
No separate shaping tool for every single rib with view on tapered
leading edges necessary – last form giving step can be done by milling
•
Simple high efficient flat plates can be used for every rib design
•
New options for welding technique due to unhindered plastic
deformation of short fiber reinforced flange material during welding
•
Use of well known and cost effective basic technology derived from
automotive industry
•
Avoiding of riveting within aircraft structures
•
Usage of high inherent strength of short fiber reinforced CF-PEEK
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Achieved results:
•
Over injection molding in general
applicable for rib flanges
•
Quality extremely depends on process
parameters of injection
•
Procedure not applicable for prototype
structures due to costs of a single tooling
•
Process reliability not sufficient up to now
Short fibre material
Laminate
Decision: For manufacturing of generic
leading edge structure an alternative
pressing technology was chosen
Micrograph of achievable
quality
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Basic structure: Pressed sandwich plate
Alternative: Local attached short
fiber reinforced material
Short fiber
reinforced material
Continuous fiber
reinforced material
Caution: Combination
of mentioned material
leads to high internal
stresses ->
Generalized rib after milling
A process avoiding
these stresses is still
under development
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The Future for Composites
Aileron Jack Fairings
J-Nose
Keel Beam Ribs
Engine Pylon Panel
Aileron Ribs
Source: Airbus Deutschland GmbH
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Application: J-Nose (Airbus)
Source: Ten Cate Advanced Composites
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Manufacturing: Cost Reduction
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Application: Ribs
Ribs are riveted (Hybrid
structures)
Complete structures made of
thermoplastic composites
should be welded or bonded.
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Manufacturing: Cost Reduction through
New Thermoplastic Materials
Cost Evaluation Landing Flap Ribs Dornier 328
Rib press formed from
a plate in one step.
Metal parts need more
forming steps.
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Application: Beams
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Application:
Flaps (moulded ribs, folded trailing edge)
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The 777 Used Advanced Materials
for Reliable and Economic Operation
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Application: Boeing Commercial
Product:
• APC-2 / AS4
Application:
• Development `Pork Chop` Ribs
• Development Strut Access Door
Manufacturer:
• Boeing Commercial
Features:
• Press or stamp formed
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Manufacturing: Boeing Commercial
Product:
• APC-2 / AS4
Application:
• Development Wing Ribs
Manufacturer:
• Boeing Commercial
Features:
• Pressclave and Diaphragm forming
• Integral ribs
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Application: Dassault Rafale
Product:
• APC-2 / AS4
Application:
• Engine Tunnel
Manufacturer:
• Dassault Aviation
Features:
• Welding of stiffener to skin
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Application: Lockheed Martin F - 22
Product:
• APC-2 / IM 7
Application:
• Weapons Bay Doors
• Undercarriage Doors
• Forward Fuselage Components
Manufacturer:
• Lockheed Martin
• Superform USA
Features:
• Superplastic Diaphragm forming
• Dual Resin Bonding
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Application: Ruder (DLR)
Comparison of Manufacturing Cost: Thermoset (100 %) / Thermoplastic version (71,79 % )
Manufacturing Technology for the Thermoplastic Version: Vacuum Consolidation Technique
Source: Institute of Structures and Design, DLR
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Application: Augusta Westland EH 101
Product:
• APC-2 / AS4
Application:
• Floor Panels
Manufacturer:
• Cytec Engineered
Materials / Augusta
Features:
• Textured surface
moulded onto upper
panels
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Application: Impact endangered parts (DLR)
Impact endangered
area
• Access panel made out of
continuous fibre reinforced
thermoplastic (CF-PEEK).
• Lightweight construction and
cost effective manufacturing.
• Fuel tightness after impact
caused by a tyre burst in the
integral fuel tank region
(Impact).
Source: Institute of Structures and Design, DLR
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Application in Automotive: Door Frame
High performance, thin-walled door frame made out of
glass fibre reinforced thermoplastic
Work share
BMW AG - DLR
Window frame and
substructure door frame
for a passenger car
Förderkennzeichen 03M 10444 8
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Stamping of Sheet Thermoplastics
Stamping time of sheet-thermoplastic comparable to process
time of sheet-metal
Temperature in the infra-red
heating area: 160-500 °C
Heating time:
Transportation
time: 2-3 sec
70-85 sec
Total process time: 74-93 sec
Temperature in the
Mould:
60 -160 °C
Pressure:
5 bar
Forming time: 2-5 sec
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Application in Automotive: Suspension Arm
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Application in Automotive: Seat Back Rest
Over Injection Moulding
Combination of continuous fibre
reinforced thermoplastics (stiffness
and strengths) and short fibre
reinforced thermoplastics
Advantage in Price
Higher stiffness and strengths
than short fibre reinforced
thermoplastics
Processing from continuous fibre
reinforced thermoplastics scrap
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Content
Conclusion
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Conclusion
Reduction of structural weight of aircraft
Improvement of durability of composite components
Reduction of manufacturing lead-times
No chemistry during processing
Manufacture complex parts in singe step
Integrate fabrication & assembly
Recycling of waste and parts of service
Despite higher material cost for thermoplastic
materials, an economic manufacturing is possible.
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Acknowledgement
For the support during the preparation of this lecture, we thank
below people and companies:
Airbus Deutschland GmbH, Mr. Ch. Rückert
Ten Cate Advanced Composite, Mr. W.H.M. van Dreumel
Cytec Engineered Materials, Mr. D. Leach
After 37 years in developing of technologies for reinforced
thermoplastic material, Mr. G. Kempe has gone into retirement at
the end of September 2006.
I would like to thank him for his loyalty, his responsibility and his
work during the last years at the Institute and in the department.
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Thank you for your attention!
Thanks to:
Frank Kocian, Günter Kempe, Rüdiger Keck, Thomas Hetzel et. al.
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Manufacturing

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