intales 18 october2018€¦ · composite parts. 3d-lighttrans a project co-funded by the ec in the...
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INTALES18 October 2018
www.3D-LightTrans.com
Marianne HörlesbergerAIT Austrian Institute of Technology
Project Management of 3D-LightTrans
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
AIT Austrian Institute of Technology
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Infrastructure Systems
Next Generation Solutions
Applied ResearchSystem Competence
bmvit
Tomorrow Today
Austria‘s largestRTO
Federation ofAustrian Industries
Centers8employees1,300
over
m EUR total revenue143
SubsidiaryEnterprises
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
The Core Idea of 3D-LightTransLarge scale manufacturing technology for high-performance lightweight 3D multifunctional composites
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Project Objectivesto establish and provide access to ground breaking, highly flexible and adaptable low-cost production technologies
for manufacturing high performance light weight
3D multifunctional textile reinforced polymer composites
for structural components.
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
State of the Art (when 3D-LightTrans started)
MANUFACTURING CHAIN
Transfer Preform onto toolautomated
Thermal Pressingautomated
THER
MO
FOR
MIN
G
Fixation
DrapingInfiltration
PREPR
EG A
UTO
CLAVE O
R
CO
MPR
ESSION
MO
ULD
ING
Place Material on Tool
Manual
Drape or Deform
Manual
Tool Pre‐Head and Cure
Slow
Storage/Transport
Low Temperature
PRE-
FOR
MIN
G
Pre‐heat & Transfer to Tool
Tool Pre‐Head
Drape/Preform
Cure
Slow
PrepregFabric
Matrix
Up to an hour
Inject Thermoset Resin
Yarn
Weaving Fabric
Matrix
Weaving
Hybrid Fabric
Hybrid YarnWeaving
Air co‐mingling
Yarn Matrix
3D-LightTrans MANUFACTURING CHAIN
RESIN
TRA
NSFER
M
OU
LDIN
G (R
TM)
Up to several hours
Yarn
PRE-FO
RM
ING
1-5 minutes
Preform
Storage/ TransportROOM
Temperature
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
The 3D-LightTrans Concept
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Hybrid yarnMultilayeredand spacer fabrics
Draped and fixated pre-form
Thermo-pressed final composite parts
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Our Innovation in a Nutshell
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Hybrid yarn Woven fabric Automation Consolidation
• Reduction of fibre displacement during thermoforming > 50%
• Reduction of composite forming time > 50% (with thermoforming and off-the-tool draping)
• Automated draping with rolling/sliding double action robot gripper and force control
• Novel process for geometry fixation
• Manufacturing chain suitable for mass production
• Industrial weaving of cross woven spacer fabrics in one-shot-process
• Significant reduction of yarn abrasion
• Multilayers with additional Z reinforcement
• Double reed for high warp density
• High homogeneity of the glass/polymer distribution
• High reproducibility & speed (500 m/min)
• Flexibility in the choice of yarn (e.g. 70:40, 70/30, 80/20 mass content PP/Glass or PET/Glass, 600-2000tex)
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
The Consortium
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Results – New FindingsIssues for the
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Air-Mingling Yarn Developed yarn architecture Upscaling of the air-mingling
process at PD-GOschatz to TRL 6
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Commingled hybrid yarn
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Dornier – New Loom
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Michel Van De Wiele – New Loom TRL 6-7
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TUD
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Pre-Fixation fixation process using milled black PET powder and melting it by laser is
verified
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Thermo-Pressing
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Joining / Metal Part Integration
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Demonstrator Spare Wheel Well
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Demonstrator Tailgate
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Handling and Draping
Handling systems join robotic systems
One handling device for the 3 main workstations• Textile cutting• Draping • Thermoforming
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Robot for Draping
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Model for Manufacturing Chain
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Multi-Scale Mechanical Modeling
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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Meso-scale modelling of dry fabrics
Meso-scale modelling of thermoformed composite, taking into account small misalignments
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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Draping simulations of tailgate (left) and spare wheel well (right)
Thermoforming simulation of tailgateSimulation of complete process chain
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Manufacturing Value-Added Cost (MVA)
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Based on the time spent in the specific manufacturing step, (calculated in the previous
simulations), the energy cost ( ) is obtained.
Energy Cost
· ·
Manufacturing Value-added Cost
· ·
The calculated results can guide changes to the commodities and assembling stations and provide invaluable information to the capacity planners and schedulers to estimate the required number of processing stations and resources to meet the customer demand.
the energy consumed per unit of time per processing step
time spent in the specific processing step; i.e., time in which the processing station is working
unit cost of energy
incurred processing cost per unit of time per processing step
resource cost per unit of time per resource used
cost of the scrapped partscost of the energy
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Optimization and Scaling-up of the Production Process
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In this part of the project the functional relationships between various factors will be investigated in order to find the better configuration (i.e., optimal configuration) for the manufacturing process, as well as to investigate the parameters driving the scaling-up.
Objective Function
· ·1π λ θ ξ ζ
χ∑ ∑ ∑ · · 1π λ
∑ ∑ ∑ · · 1π λ φmin , τ
This objective function needs to be implemented in a post processing module and investigated
using Design of Experiment and Response Surface Methodology (Steppan et al., 1998).
SCHEDULED PRODUCTION S REALIZED PRODUCTION R
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Life Cycle Assessment (LCA)
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EU
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
LCIA – Tailgate Use Phase
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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Life Cycle Analysis Conclusions
Along the whole life cycle, the 3D-LT solution shows:
Advantages in use phase thanks tothe light weighting
The benefits in use phase are, anyway, not enough to balance the environmental burdens in production
Anyway, the commingling step, the most environmentally critical, could be further improved/optimized
Use of recycled material could improve significantly the 3D-LT solution (check on the quality requirements)
3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Scientific Output 3 publication in reviewed journals 10 further contributions to conferences (presentations and posters) 6 invited presentations 4 contributions in newsletters 3 PhD theses
Jean Emile ROCHER, UORLExperimental characterization and modelling of the mechanical behaviour of 3D comingled
composite reinforcements
Stefan JACQUES, UGentDevelopment of a Framework for the Construction of Meso-Scale Finite Element Models of
Textile Composite
Matthias Hübner, TU DresdenDrapingsimulation
1 Master Thesis Andrea DIETRE, CRF / University Trento
Development of an Automotive Component in Thermoplastic Composite Material
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Three Years After Bentley is still considering the use of thermoplastic composite structures for
secondary (trim substrate) structures. the 3D-LightTrans approach remains valid, with some modification.
Van De Wiele 3-LightTrans opened up a bigger international exposure of Van De
Wiele as a possible contact in composites related production, both in industrial and in research environments. No real 3D-LightTrans machine sales have been realized, but some
specialty machines have been sold to new contacts.
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
Three Years After TU Dresden / ITM 3D-LightTrans project is still alive: further development in the
lightweight material arena; Working very closely with the industry partners during the project helped to develop more innovative ideas that can fulfill the requirements of industry.
LKR (AIT) 3D-LightTrans was to gain experience in joining fibre reinforced
plastic with metals via pin technology. Since this project, LKR has further grown in the field of pin-
technology. Every year we receive contract research requests for the pin-
technology – the last once were for automotive and marine application.
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
3D-LightTrans
A project co-founded by the European Commission under the 7th Framework Program within the NMP thematic area.
THEME: NMP-2010-3.4-1Manufacturing systems for 3D-shaped, multilayered products based on flexible materials
Full Title: ”Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites“
Grant agreement no: 263223
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3D-LightTrans
A Project co-funded by the EC in the 7th Framework Programme
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Marianne Hö[email protected]
Project Management of 3D-LightTrans