textile composite ii vps
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Textile Preforms
V.P.Senthilkumar11MT71
Production Technologies for Composites
Non-crimp fabrics (NCF)
Prepregging
Braids
3D-preforming
OverbraidingITA
NCF machine NCF
Strategies for Future Preforming
• Tailored Braids
• Tailored NCFs
• Automated Preform Assembly
Preforming technology
The three major challenges for the production of textile preforms
• Reduction of cycle times
• Reduction of costs
• Production of complex parts in large
numbers
BMW I3 car body
Motivation for Research in Composites
• Fiber reinforced plastics (FRP) are a promising engineering material for:
• Aerospace• Automotive industry• High-end machine parts• Wind energy
Motivation for Research in Composites
Why FRP for conventional vehicles?
• Emissions: 100 kg car weight ≈ 9 g CO2 per km[2] • Fuel consumption: 100 kg car weight ≈ 0.4l per 100 km[2] • Improved safety • Higher accelerations
Why FRP for electrically driven vehicles?
• Critical distance range • Expensive batteries • Integration of functionality
1. Source BMW
2. Source Audi
Motivation for Research in Composites
The production of FRP parts in high volume can be realised by means of Preforming-Liquid Composite Moulding (LCM) processes
• Short cycle times
• Heavy tow material can be used
• Complex designs
• High amount of manual labour
For composite materials, there is a close interaction Between * Production processes * Part design * Material properties
Future Preforms
WeavingWeaving NCFNCFBraidingBraiding
RovingRoving
Fibre placement
Fibre placement
Multi step preform
Multi step preform
Preform assemblyPreform assembly3DPreform
3DPreform
3D Weaving3D Weaving
3DPreform
3DPreform
Single-step preforming
Multi-step preforming
Strategy For Future Preforms
• Combination of single-step and multi-step preforming
• Single-step: Production tailored textiles with locally adjusted properties
• Multi-step: Automated assembly of tailored textiles into complex preforms
Single-step preforming(Tailored-NCF)
Tailored-Braid Multi-step preforming
Pref
orm
ing
Tailored Blank Tailored Tube Assembly line
Source: Thyssen Krupp Source: Thyssen Krupp
Stee
l pr
oces
sing
Source: KUKA
Single-step preforming(Tailored-NCF)
Tailored-Braid Multi-step preforming
Pref
orm
ing
Tailored Blank Tailored Tube Assembly line
Source: Thyssen Krupp Source: Thyssen Krupp
Stee
l pr
oces
sing
Source: KUKA
Tailored Braids
Process Overview
Roving
(3D Fiber Weaving) placement
3D sub-preform
Braiding
Preform assembly
Multi-step preform
Warp-Weaving knitting
2D preform
Tailored braids
• Overbraiding technology
Two groups of bobbins moving on concentric circles
Mandrel is moved through braiding eye
Tubular braid is laid down on shaped mandrel
Bobbin path in radial braiding
ITA
Radial braiding machine
Tailored braids
• Overbraiding technology
Economic production of near-net shape textile preforms
0°-layers possible
Automation possible
Wide range of materials
Braiding of ceramic fibers Braiding of 0°-layer
Tailored braids
• 3D-rotary braiding technology• Independent bobbin movement• Highly complex structures• Fully interlaced structures
Tailored braids
Examples for 3D-rotary braids
3D-braided T-profile Preform for crash-absorber with integrated flange
10 mm
Continuous change of cross section 3D-braided branching
16
Tailored braids
Challenges braiding technology
• High productivity
• Complex geometries
• No continuous production
if thickness changes
• More possibilities in
production than in
simulation
• Simulation
• Mechanical parameters
• Design tools
• Modification of thickness
• Braiding speed
Tailored NCFs
Process Overview
Roving
(3D Fiber Weaving) placement
3D sub-preform
Braiding
Preform assembly
Multi-step preform
Warp-Weaving knitting
2D preform
Tailored NCFs
Multiaxial non-crimp fabrics (NCFs)
0°-Layer supply
Creel for rovings
Production direction
Take-up
Warp-knitting unit
Computer controlled weft-insertion-systems
Warp-knittting machine [LIBA Maschinenfabrik GmbH]
Tailored non-crimp fabrics
Production of near-netshaped semi-finished parts in one production process
Non-crimp fabrics (NCF) with
locally adjusted properties
allowing different
• Thickness
• Bending stiffness
• Drapability
Benefits for preforming
• Less cutting operations
• Less cutting waste (up to 60 %)
• Less handling operations
Schematic structure of multiaxial warp-knit
[LIBA GmbH]
Automated preform assembly
WeavingWeaving NCFNCFBraidingBraiding
RovingRoving
Fiber placement
Fiber placement
Multi step preform
Multi step preform
Preform assemblyPreform assembly3DPreform
3DPreform
(3D Weaving)
(3D Weaving)
3DPreform
3DPreform
Automated
Automated preform assembly
HandlingDrapingHandlingDraping
Quality controlQuality control
CuttingCutting AssemblingAssembling
preform centre
7 m
5 m
Automated preform assembly – step 1: 3-D cutting
Robotically guided cutting device Ultrasonic knife Cutting of complex geometries
Robot
TextileKnife
Housing
Ultrasonic 3D-cutter
Automated preform assembly – step 2: handling
Needle grippers
Cryo grippers
Vacuum technology
Needle gripper Cryo gripper Vacuum technology
Pick and place operation at preform centre
Automated Preform Assembly – step 3: quality control
Online quality control Texture (material, textile type) Orientation and geometry of textiles Defects in textiles
Monitoring head
Lighting module
Lasersensor
Casing
Camera
Robot flange
Interface
Digital image processing
Automated preform assembly – step 4: assembling
Sewingtechnology
SewingKSL-tufting
SewingKSL-blind stitch
BinderHot melt
Automated Preform Assembly
Tailored binder application • Robotically guided
• Local application
• Different binder materials
• Varying binder quantities Local binder application
Novel binder activation • Activation by hot air
• Compression of preform
• Robust system with low invest
• Modular system
Novel binder activation device
Automated Preform Assembly
Exemplary process chain for the automated production
of binder-preforms
Loop
cutting handling Binder
application Binder
handling activation
Summary
Automated preforming process vs. existing technologies: Lower cycle times Less waste (down by 60 %) Lower costs Complex parts in large numbers
→Mass production of composites
Properties of some textile performs
Textile Preform
Advantage Limitation
Low crimp, uniweave
High in-plane properties; good taliorability; highly automated preform fabrication process
Low transverse and out-of-plane properties; poor fabric stability; labor intensive ply lay-up
2-D Woven Good in-plane properties; good drapability; highly automated perform fabrication process; integrally woven shapes possible; suited for large area coverage and extensive data base
Limited taliorability for off-axis properties ; low out-of-plane properties
Properties of some textile performs
Textile Preform
Advantage Limitation
3-D Woven Moderate in-plane and out-of-plane properties; automated preform fabrication process and limited woven shapes are possible
Limited taliorability for off-axis properties and poor drapability
2-D Braid Good balance in off-axis properties; automated preform fabrication process; well suited for complex curved shapes; good drapability
Size limitation due to machine availability and low out-of-plane properties
Properties of some textile performs
Textile Preform Advantage Limitation
3-D Braid Good balance in in-plane and out-of-plane properties; well suited for complex shapes
Slow preform fabrication process; size limitation due to machine availability
Multi-axial warp knit Good taliorability for balanced in-plane properties; highly automated preform fabrication process; multi-layer high throughput; material suited for large area coverage
Low out-of-plane properties
Stitched fabrics Good in-plane properties; highly automated process; provides excellent damage tolerance and out-of-plane strength and excellent assembly aid
Small reduction in in-plane properties; poor accessibility to complex curved shapes