An Introduction to the 3D LightTrans Project Developing Multi-Material Vehicles With Composite Parts to Identify Significant Weight Reduction

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1 An Introduction to the 3D LightTrans Project Developing Multi-Material Vehicles With Composite Parts to Identify Significant Weight Reduction Opportunities Lee Bateup, Bentley Motors

2 Presentation Contents Brief Overview of 3DLightTrans Project & Objectives Description of the Project Detail Progress & Highlights Next Steps & Future Planning Questions & Discussion Points GALM, 24 th April 2013 Lee Bateup, Bentley Motors 2

3 Overview - Project Objectives to 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 GALM, 24 th April 2013 Lee Bateup, Bentley Motors 3

4 Overview - Project Objectives GALM, 24 th April 2013 Lee Bateup, Bentley Motors 4

Overview - Project Objectives Current State of the

CHAIN Yarn Matrix Matrix Yarn Matrix Yarn Weaving

Fabric Weaving PRE-FORMING RESIN TRANSFER MOULDING

Tool Pre- Heat Inject Thermoset Resin Cure SLOW

COMPRESSION MOULDING Infiltration Storage/Transport

or Deform Manual Tool Pre- Heat and Cure SLOW

THERMOFORMING Drape Fixation Storage/Transport ROOM

Thermal Pressing Automated Hybrid Fabric Preform 1-5

5 Overview - Project Objectives Current State of the Art MANUFACTURING CHAIN 3D LightTrans MANUFACTURING CHAIN Yarn Matrix Matrix Yarn Matrix Yarn Weaving Air Co- mingling Hybrid Yarn Automation Weaving Fabric Weaving PRE-FORMING RESIN TRANSFER MOULDING (RTM) Pre- heat & Transfer to Tool Drape/ Preform Tool Pre- Heat Inject Thermoset Resin Cure SLOW Fabric Up to an hour PREPREG AUTOCLAVE OR COMPRESSION MOULDING Infiltration Storage/Transport LOW Temperature Place Material on Tool Manual Drape or Deform Manual Tool Pre- Heat and Cure SLOW Prepreg Up to several hours PRE-FORMING THERMOFORMING Drape Fixation Storage/Transport ROOM Temperature Transfer Preform onto Tool Automated Thermal Pressing Automated Hybrid Fabric Preform 1-5 minutes Repeatability Automation Rate Quality Cost GALM, 24 th April 2013 Lee Bateup, Bentley Motors 5

6 Project Description Partner Companies 1 Austrian Institute of Technology Austria 2 Xedera Austria 3 Centro Ricerche Fiat Orleans Italy 4 Coatema Germany Trento 5 Federal Mogul Systems Protection France 6 University of Ghent Ghent Belgium 7 Grad Zero Espace Florence Italy 8 Technical University of Dresden Germany 9 Leitat Paris Spain 10 Lindauer Dornier Germany Vienna 11 NWTexNet UK 12 PD- G Oschatz Germany 13 Michel Van de Weile Barcelona Belgium 14 ONERA France 15 Bentley Motors Prague UK 16 SVUM Czech Republic Dresden 17 Promaut Spain 18 University of Orleans France GALM, 24 th April 2013 Lee Bateup, Bentley Motors 6

Project Description Workpackage Structure WP2 Modelling, Simulation & Validation WP1 Products & Process Requirements WP3 Manufacturing Processes for

Sided Weaving Multi- Layer Fabrics with Complex 3D Geometry Adhesive Application On- Line Online Fixation Draping & Fixation of Complex 3D Geometry WP4

Demonstration WP5 Manufacturing Chain Integration Handling & Transportation Scale- up New Supply Process Chain Testing & Quality Life Cycle Analysis

7 Project Description Workpackage Structure WP2 Modelling, Simulation & Validation WP1 Products & Process Requirements WP3 Manufacturing Processes for Textile Construction Yarn Hybrid Yarn Raw Fibre (glass) 3D Textile Construction (Spacer Fabrics) for Function Integration Multi- Layer Weaving Double Sided Weaving Multi- Layer Fabrics with Complex 3D Geometry Adhesive Application On- Line Online Fixation Draping & Fixation of Complex 3D Geometry WP4 Manufacturing Processes for Final Compound Product Thermo- Press Process (Primary Route) Resin Transfer Process (Secondary Route) WP7 Exploitation & Demonstration WP5 Manufacturing Chain Integration Handling & Transportation Scale- up New Supply Process Chain Testing & Quality Life Cycle Analysis Repair & Recycling WP6 Demonstration Interior Trim Substrate Tailgate Spare Wheel Well WP8 Coordination & Project Management GALM, 24 th April 2013 Lee Bateup, Bentley Motors 7

8 Project Description Selection of Demonstrators GMT CF/Epoxy Higher performance Lower Cost Lower Cost GALM, 24 th April 2013 Lee Bateup, Bentley Motors 8

9 Project Description Manufacturing Chain GALM, 24 th April 2013 Lee Bateup, Bentley Motors 9

10 Step 1 - Yarn Comingling Technologies Contrast twining of reinforcement and polymer fibres to produce low damage product, suitable for weaving E-Glass PP: 32 GPa E-Glass PET: 36 GPa GALM, 24 th April 2013 Lee Bateup, Bentley Motors 10

11 Step 2 - Textile Technologies Preforms manufactured using advanced weaving technologies, from co-mingled yarn. 3D shape fabrics Multi-layered fabrics GALM, 24 th April 2013 Lee Bateup, Bentley Motors 11

Step 2 Modelling Fabric Architecture Simple geometry of 3D

representative of actual geometry Multiple interactions and

to complexity Increased complexity of model More representative of

and convergence issues remain Process model to improve accuracy

12 Step 2 Modelling Fabric Architecture Simple geometry of 3D architechture Satisfactory for visualisation of fabric Not representative of actual geometry Multiple interactions and contact conditions in the unit cell Model convergence unlikely due to complexity Increased complexity of model More representative of the real textile Still many compromises and assumptions Contact and convergence issues remain Process model to improve accuracy More representative of final geometry Explicit analysis, reproduces compression of Textile 12

Binder thread woven into fabric Heat energy used to locally fuse binder Xenon

13 Step 3 Pre-fixation & Draping Pre-Fixation aids handling & provides consistent drape mechanisms. Binder thread woven into fabric Heat energy used to locally fuse binder Xenon flash Contact (conductive) heat-transfer Multiple drape methodologies considered Manipulation with robotic grippers Stamping & forming 13

14 Step 3 Modelling Drape & Pre-fixation Method Pre-Fixation Decision 1. Model draped textile to establish fibre angle distribution 2. Transfer fibre angle to plane & determine fixation zone (in red) 3. Repeatable textile drape with local pre-fixation Compare Models to Experimental Results Fibre angle and shear distribution Wrinkling & defects 14

Step 3 Modelling Drape & Friction Input required to

filament PP yarns and GF yarns commingled yarns (from

and compaction of yarns geometric characterization of

frame, bending) Testing of tool/fabric friction 80 70

15 Step 3 Modelling Drape & Friction Input required to model dry fabric architectures Testing on single filament PP yarns and GF yarns commingled yarns (from bobbin and after weaving) yarn/yarn friction, bending and compaction of yarns geometric characterization of fabric architectures dry fabrics (tension, picture frame, bending) Testing of tool/fabric friction Force N ,5 1 1,5 2 elongation % 15

another cell in the same facility, or To another factory Allow inspection of the

16 Step 4 Fixation Improve handling characteristics and reduce bulk Guarantee a good quality thermoformed part Include inserts Enable the transport of the preform To another cell in the same facility, or To another factory Allow inspection of the preform for defects Wrinkles Damage or tears Mis-aligned fibres or sub-preforms 16

Step 5 Thermoforming Thermoforming Process Already

Preform sub-assembly may be required Application of

composite (minimum flow) Final thickness achieved

17 Step 5 Thermoforming Thermoforming Process Already near-nett thickness Metallic inserts in position Preform sub-assembly may be required Application of heat and pressure Re-melt thermoplastic Consolidate composite (minimum flow) Final thickness achieved Cooling phase Freeze thermoplastic Remove from tool, inspect & trim 17

1 2 3 4 A Project co-funded by the EC Step 5 Thermoformed Parts After thermoforming

Z-fibres causes wrinkling Results in waviness of in-plane fibres effect on

18 A Project co-funded by the EC Step 5 Thermoformed Parts After thermoforming Final reduction of thickness Less than 50% of textile Risk of porosity Compression of Z-fibres causes wrinkling Results in waviness of in-plane fibres effect on longitudinal stiffness and not easy to construct representative volume element

19 Step 5 Impact Behaviour & Strain Rate Effects High Strain Rate Thermoplastic materials exhibit changes Increased stiffness & strength Impact Behaviour Higher toughness than thermoset materials Expectation of improved impact performance Additional complexity of weave architecture Higher resistance to delamination 19

20 Step 5 Thermoformed Parts (Simulation) Simulation Tasks Simulate the effect of waviness of the inplane weft and warp yarns on the elastic properties Simulate the effect of porosity on the elastic properties Simulate impact behaviour and compare to experimental results 20

Multi-Objective Design Optimisation Tailgate as

data Initial geometry optimisation Thickness

8mm) Limit torsional and lateral deflection

constraints Fibre orientation balance (warp,

21 Multi-Objective Design Optimisation Tailgate as Benchmark Example Multilayered fabric (3.0mm) to replace pressed steel (0.7mm) Properties determined from experimental data Initial geometry optimisation Thickness optimisation step Apply thickness envelope (1mm 8mm) Limit torsional and lateral deflection Minimum mass objective Introduce manufacturing constraints Fibre orientation balance (warp, weft, z) Maximum thickness of fabric at width (warp creel) Utilise 3D shaped fabric 21

22 Summary Progress & Highlights Identify and Develop Design Requirements for Demonstrators Interior trim substrate Tailgate Spare Wheel Well Develop Material Technology Comingled yarns Woven fabrics Establish Manufacturing Chain Pre-fixation Pre-forming Fixation Thermoforming Create & Validate Modelling Tools Manufacturing Chain Fabric Behaviour Thermoformed Material Properties 22

Next Steps & Future Planning Multi-Objective Design Optimisation Interior trim substrate Tailgate Spare Wheel Well Develop Glass/PET material solutions Further validation of modelling techniques and

23 Next Steps & Future Planning Multi-Objective Design Optimisation Interior trim substrate Tailgate Spare Wheel Well Develop Glass/PET material solutions Further validation of modelling techniques and tool-box Improved properties across the operating temperature range Demonstrate Fastening/Bonding Technology Identify mechanical fastening solutions Demonstrate adhesive bonding and thermoplastic welding methods Demonstrate Supply Chain capability Manufacture demonstrators 23

24 Question Time Thank You for Attention 24

THERMOPLASTIC COMPOSITE PARTS BASED ON ONLINE SPUN COMMINGLED HYBRID YARNS WITH CONTINUOUS CURVILINEAR FIBRE PATTERNS

THERMOPLASTIC COMPOSITE PARTS BASED ON ONLINE SPUN COMMINGLED HYBRID YARNS WITH CONTINUOUS CURVILINEAR FIBRE PATTERNS E. Richter a*, K. Uhlig a, A. Spickenheuer a, L. Bittrich a, E. Mäder a,b, G. Heinrich