SAMPE Seminar on Advances in Automated Composites Manufacturing

Transcription

1 Automated Method of Composite Manufacture for Aero Engines SAMPE Seminar on Advances in Automated Composites Manufacturing Ashan Amarasinghe ROLLS-ROYCE PLC 24 th February 2011 The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

2 Composites in Gas Turbines 2 The focus of this presentation is on Automated Prepreg Preform Manufacture for PMC Components Woven & Braided automated preform manufacture is also used extensively on certain engine components Likewise there are also applications of CMCs and MMCs with associated methods of manufacture Contents Introduction Slides Component Applications Slide 05 Manufacturing Process Selection Slide Managing Knowledge Gaps & DFM Slide 11 Conclusion Slide 12

3 3 Reducing Carbon Emissions in Aerospace The Advisory Council for Aeronautics Research in Europe (ACARE) has set technology goals to achieve by % reduction in CO 2 per passenger kilometre 80% reduction in NOx emissions and 50% reduction in noise 0% -10% -20% -30% Contributions to CO 2 reduction -40% -50% Engines Airframe Air traffic management and operations Report of the Group of Personalities : Vision for 2020 (Jan 2001) 3

4 Benefits of Composites 4 Advanced manufacturing programmes are essential to ensure the technology can be delivered affordably Pi Prime opportunity for UK manufacturing industry

5 5 Component Application By pass duct (2 shaft)

6 Manufacturing Challenges 6 Low Cost Minimal Labour Low Material waste Low Recurring costs Low CapEx High OEE High Volume High production rate Low takt-time time Very low scrap rate Zero Waste High Quality Good component mechanical performance Close geometric tolerance Ability cope with high component complexity Tight control of defects High process repeatability & reliability (reliable means of data collection) Moderate or High process maturity

7 7 Lay-up Automation Ply collation remains as one of the highest cost areas of composite part fabrication, normally representing 40-60% of the part fabrication cost. Difficult balance between Production Rate, Labour, Equipment Cost, Material Deposition Rate, Material Usage, Component Performance Knock-downs and Process/Equipment Maturity. AFP and ATL methods of preform manufacture offer the potential of high deposition rates and consistency on reasonably complex geometry. With respect to prepreg lay-up, AFP and ATL processes provide significant reductions in material scrap. For AFP since the tows are added-in and taken-out as they are needed, there is very little wasted material - scrap rates of under 10% are common. Automated preform manufacturing methods utilising dry fibre provides high repeatability, relatively lower machine & labour costs, and significant savings in material costs & material scrap. These methods however require additional processing prior to cure (i.e. resin injection) and have relatively low preform production rates compared to ATL & AFP.

8 Potential Manufacturing Routes Conventional Tow/Tape Lay-Up Fibre Place Weave/Braid 8 Input Material Prepreg sheet Prepreg Tow/Tape Dry Fibre with Binder Dry Fibre Preform Hand Lay-Up ATL/AFP DFP Weave/Braid Cure / Form Autoclave / OoA Autoclave/ OoA RTM / RI RTM / RI / VARTM Finish Composite Machine Machine Machine Machine Assemble& Finish Finishing Finishing Finishing Finishing * The degree of machining required will be dependent upon the use of matched moulds, caul plates or bagging during cure. * Finishing includes surface preparation for bonding etc.

9 9 Automated Methods of Manufacture Automated Preform Manufacturing Technology Prepreg Dry Fibre ATL AFP Wrap DFP FW Weaving Braiding 1. Automated Dynamics Corp. 2. Accudyne Systems Inc. 3. Coriolis Composites 4. ElectroImpact 5. Forest-Linẽ Group 6. Ingersoll Machine Tools 7. MAG Cincinnati 8. M.Torres Group Listed alphabetically Reinforcement Pick & Place Forming Pinning Tufting Stitching Diaphragm Press SAMPE Rolls-Royce Seminar Proprietary on Advances in Automated Composites Manufacturing Rolls-Royce 24 th Feb 2011

10 Fundamentals of AFP & ATL Tow Guide AFP Multiple 6.35mm Tow Creels Multiple Backer Removal Spools Individual Add/Feed Rollers Individual Mechanical Knives Individual Nip Rollers 10 Conformable Roller ATL IR lay Surface Heater Single 150mm Tape Creel Add/Feed Rollers Single Backer Removal Spool Ultra-sonic Knife Conformable Roller IR lay Surface Heater

11 Managing Knowledge Gaps & Addressing DFM 11 Lay-up Tolerances What are the Gap & Lap tolerances that does not significantly affect performance? Rules for Seed point generation and Ply Splitting? Traditional material characterisation strategies must be re-assessed AFP & ATL processes affect material performance criteria Implications in local material properties, and therefore modelling approach Level of realism in the simulation models Is a 30 degree ply actually a 30 degree ply when laid? Need tools which transfer fibre orientations, volume fractions, ply thickness variation, etc..., to FEA tools Existing tools for simple ply lay-up modelling; drape, ply templates, etc, are good and well integrated, BUT Need tools which model through thickness reinforced preforms (e.g. 3D woven or 3D braided preforms, stitching etc.) Need tools which predict fibre placement and fibre/resin volume fraction postcure

12 Automated Method of Composite Manufacture for Aero Engines Conclusions 12 Significant progress has been made in utilising AFP & ATL Technology in complex composite engine component manufacture. There is still significant opportunity to further develop AFP & ATL machine to better support mass composite engine component manufacture. A major challenge still exists in the availability of software and FEA code that will allow better modelling of the AFP process in particular. Significant work is also required in characterisation, assessment and understanding of potential physical performance knock-downs due to feature and defects generated by the AFP & ATL processes of manufacturing. Automated in-process inspection and measurement capability remains a key area of interest t in the productionisation i of the AFP process in particular.

13 Thank You. The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.