braiding technology: machine concepts, processes...

Prof. Klaus Drechsler

SGL Institute for Carbon Composites, TU München

Fraunhofer IGCV, Augsburg

Braiding Technology: Machine Concepts, Processes and Applications

JEC Conference

March 2017

• History of braiding and other textile technologies

• Requirements for high performance composites

• In-direct preforming technologies

• Direct preforming technologies

• Exemplary applications of braiding technologies

• Future challenges

Overview

19.09.2013 2History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof.

Drechsler_Leuven 09/2013

Ideas to improve interlaminar strength

• 3D braiding

The history of textile technologies for composites



3 dimensional braiding [Sun, Science Direct, 2004]

mandrel

pull unit

3D braiding machine [Guyader, 2013]

• 3D-stitching reinforcement




Computer-controlled „Advanced Stitching Machine (ASM)“, developed by NASA and Boeing

Application:Attachement of dry stringers on fueslage skin, upto a length of 12m and a thickness of 38mm with3200 stitches per minute

• 3D weaving




3D weaving looms for thick part manufacturing based on needle (a) and rapier (b) principles[King, 1977; Fukuta, 1974], production of 3D orthogonal fabrics

(a) (b)

Weaving loom producing 3D orthogonal wovenfabrics [Mohamed / Zhang, 1992]

3D orthogonal fabric [Bilisik, 2009]

• Multiaxis 3D woven fabric• Multiaxis pultruded rod fabric [Kimbara, 1991]; prototype stage

• Extension of lappet weaving; commercial stage




Multiaxis weaving [Ruzand / Guenot, 1994]

• Multiaxis 3D woven fabric• Multiaxis 3D weaving [Mohamed / Bilisik, 1995 / 2010]; prototype stage

• Modified 3D lattice weaving [Khokar, 2002]; prototype stage

• Multilayer narrow weaving principle; prototype stage

• Application: structures as connector to structural elemensts of aircraft components




Multiaxis weaving loom [Bryn / Nayfeh, 2004 / 2006]

• 3D circular weaving [Bilisik, 2000 / 2010]• On the basis of 3D braiding principle




Woven preform Weaving loom [Yasui, 1992]

Conditions for High-Performance Composites

Fibre materialFibre volume fraction

Fibre length

2τ

σDLc

Fibre orientation

1

T TQTQ

19.09.2013History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof.


Challenges for Automotive Applications

Rework

Process

Material

Rework

Process

Material

co

sts

Up-to-

date

Aim

- 50%

- 90%

- 70%

Need for Action

14.03.2012 Prof. Dr.-Ing. Klaus Drechsler 10

[MAICarbon]



Direct and Indirect Preforming – Process Chain



Production of textile

CAD-based cutting

Stacking & Assembling

Infusion set-up

Introduction of resin

Binder activation sewing

Pick and Place/Drape

WeavingWarp KnittingUnstiched NCF

Direct Preform production

DrapeingPick & Drape

RoboMAGFPP

BraidingDry Fibre Placement

Indirect Preforming Direct Preforming

Self-adhesive Binder

- Weaving

- Warp Knitting

- Stitched & Unstitched NCFs

- Draping

- Pick and Drape

Indirect Preforming



• New machine technology

Weaving – Jacquard & ORW



reduced laminate thicknessreduced crimpfewer voids

Research topicsDevelopment of new 2/3D wovensComponent developmentGeneration of mechanical dataComparison of technologiesSpreading

3. Spread tow weaving

Multiaxial weaving Partial reinforcement

2. Open-Reed-Weave1. Jacquard-Weaving

Wirkwerkzeuge mit 6 Legebarren

Nadelbarre

Stechkamm

Zungen-nadel

Loch-nadel

Modern warp knitting machine

• Warp knitting is a loop-forming technique• Up to 50 fibres on one needle• woven fabric like structures possible by stitching with sewing

threads• no displacement with open constructions, no fraying edges,

even elongation of the structure• Warp knitting machines with double knitting head: tubes, round

nets, spacer fabrics

Warp knit with UD-carbon fibres and polyester stitching

Warp knit

Warp Knitting _ Technology



➢ Extrudable staircase hand rails

➢ Energy absorptive 3D-warp-knits

➢ Highly elastic glass warp-knits

➢ Fine wire nets for space antenna reflectors (30µm) and shielding

➢ Low voltage heating with metal and carbon

➢ Camouflage nets against IR and radar

Warp Knitting _ R & D



Fine wire net

Highly-elastic glass warp knit

Hand rail

Camouflage net

Unstitched Non crimped Fabrics_ Folding / Winding



Revolution Revolution

+

Evolution

economicalincrease in efficiency

Highly productive

lightersafer

recyling

Unstitched Non crimped Fabrics _ Folding / Winding



Innovation: Folding / Winding procedure for non-crimped fabrics

+ high productivity: 200 – 600t/a

+ low investment for machinery

Machinery concept:

• Folding and winding of UD-Tapes around a conveyor belt system

• Forming of lateral directed, one-layer UD-tapes with a folding process

• Pressing of the wound UD-tapes with a double calander

• Pull-off of the MD and winding onto a roll

- Compositence_RoboMAG

- FPP

- Braiding

- Dry Fibre Placement

Direct Preforming



Braiding machines at

Institut für Flugzeugbau IFB ; University of Stuttgart



Radial

Overbraiding

machine

176 Bobbins

Radial

Overbraiding

machine

64 bobbins

Braiding

machine for

ropes

48 Bobbins

Kuka-Robot

for mandrel

guiding

Braiding machines at

Institute for Carbon Composites ; TU München



• Double ring braiding machine of Herzog with air extraction:

• 1st ring: 60 bobbins

• 2nd ring: 84 bobbins

• 2 gates for filler threads

• Axial bobbin arrangement

• Core guidance by one robot on a linear axis

• Braiding machine is provided by BMW

• Herzog braiding machine with 128 bobbins with 4/4 tying

• Radial bobbin arrangement

• Core guidance by two robots on linear axis

• Pivoted for horizontal and vertical braiding

• Possibility of retooling for flat braids

Dry Fibre Placement



Dry fiber placement head with hot gas heater Dry fiber/binder yarn preform

Typical dry fiber placement cell (6 axis robot with 8 tow head)

Automation of preforming process _ Compositence Process



Basic concept of the process innovation:Reduction of present complex preform production up to one process step

Conventional Process -many individual processing steps

Automation of preforming process _ RoboMAG

tooling layer 1 [e.g. 90°] layer 2 [e.g. +45°] layer 3 [e.g. -45°]

UMSETZUNG

tooling

Laying head

Fixation area

Roving feeding

Car wing Preform

Fully automated layout of the preform directly from the dry fibre with maximum flexibility in fibre architecture



Advantages:

• Production of Preform in one step

• Fully automated

• Production directly from the fibre

• Minimal cutting waste

• Freely designable fibre architecture and wall thickness

• Use of all fibres, also hybrid

• Online quality assurance

Automation of preforming process _ RoboMAG



= Compositence usage of raw material

= additional consumption with conventional

NCF Process

FPP- Fibre Patch Preforming



• Procedure : • spread and bindered roving band is stored on a roll• system cuts the roving band in defined long pieces (patches)• patches are checked visually for tolerances• robot picks up the patches and places them to a defined form

SOWEMA

FPP- Fibre Patch Preforming



Patch size: 60 x 20 mmWeights: 80 g/m²Patching rate: 1 Patch/sPerformance: 720 cm²/min or 5.6 g/min

- Combination of Technologies

- Example: Roding and Airbus

Assembling of Preforms



Pick and Drape: Mechatronic Gripper systems 2010-2015

History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof. Drechsler_Leuven 09/2013

19.09.2013 28

CAE- Chain and Simulation



Assembling, Tailoring and Combination of Technologies



Braiding Cell



CTC Stade: Pilot machinery for aerospace stringers:

• Complex CFRP Stringers• Fully automated braiding

• Appr. 1600m per Aeroplane „Large-scale production“

• For A320-replacement =>40000 Stingers/year

[EADS & SGL GROUP]

BIAX-Braid 90°-winding UD-Braid

Crashtubes for:passenger cars, trucks,train, helicopter,aircraft

specific energy absorption:Composites: 60 – 100 kJ/kg iron/steel: ca. 15 kJ/kgAluminum: ca. 25 kJ/kg

Braided Crashboxes - Axialcrash



Combination of direct and indirect preforming - Roding



19.09.2013

The path to high-volume applications: MCV - BMW i3 – BMW 7 series - …

• Konzeptstudie – Megacity Vehicle • Leichtbau Struktur Konzept

(Quelle: BMW AG)


34


19.09.2013

Institute for Carbon Composites

Boltzmannstr. 1585748 GarchingGermany

Phone: +49 (0)89 / 289-15092Fax: +49 (0)89 / 289-15097

Mail: [email protected]: www.lcc.mw.tum.de

Prof. Dr.-Ing. Klaus Drechsler

braiding technology: machine concepts, processes...

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