Novel Machine Systems for MERGE Technologies

Transcription

1 CLUSTER OF EXCELLENCE MERGE EXC 1075 Novel Machine Systems for MERGE Technologies Prof. Dr.-Ing. habil. Prof. E. h. Prof. Lothar Kroll Coordinator Cluster of Excellence MERGE, TU Chemnitz Director of Institute of Lightweight Structures and affiliated institute Cetex Head of Fraunhofer Group STEX at IWU Dr.-Ing. Jürgen Tröltzsch Scientific Director Cluster of Excellence MERGE, TU Chemnitz CFK-VALLEY STADE CONVENTION 2016

2 Challenge: reduction of fleet consumption and emmission of CO2 USA Europa China 100 kg weight reduction 8,5 g/km CO 2 -reduction! CO 2 reduction is a central task, that affects all markets source: Volkswagen AG 2

3 Infrastructure 3

4 Cluster of Excellence MERGE: Facts and Figures Only two Federal Cluster of Excellence in the field of mechanical engineering, the first and only Cluster in lightweight structures About 100 scientific, technical and administrative staff MTC Lightweight Structures e. V. for industrial partners New Master s Programme Merge Technologies for Resource Efficiency, PhD-Programme Funding period: 1st November st October

5 Collaboration of research and practice 25 Principal Investigators and 13 Participating Researchers Participating Institutes 14 Institutes of TU Chemnitz, 3 institutes of TU Dresden, 7 faculties 2 Affiliated Institutes of TUC 2 Fraunhofer Institutes, 1 Leibniz Institute 18 members 44 members Member of the Excellence Council: Prof. M. Tukiendorf 5

6 Mission General Problems increasing prices of energy and raw materials climate change by greenhouse effect, global warming Requirements energy savings mass reduction Approach Merge Technologies Lightweight Structures Strategy Bivalent Resource Efficiency 6

7 In-line and In-situ Process Chains 7

8 Interacting Research Domains (IRD) Prof. Nestler Prof. Drossel Prof. Kroll Prof. Geßner 8

9 Multi-axial fabrics with warp thread stowing (MAG-KV) Textile Preform technology, upgrading of MAG-Technology In limits: variable-axial thread rest of MAG base material Very high productivity through continuous process 2D-process, 3D drape-able Good reproducibility through machine control source: Daimler Chrysler AG, Demonstrator part Fuel tank partition 10

10 Continuous Orbital Wrapping (COW)-System: Technology development Orbitalrings Main focus Continuous manufacturing of thermoplastic Prepregs constant placement speed Modulare construction Suitable for mass production Winding core Combined Tapelaying- and winding process 11

11 Continuous Orbital Wrapping (COW)-System: Prototype System 12

12 Injection Moulding Process with Integration of textile Reinforcement FiberForm-Process Pick-up of Prepregs 2. Preheating of Prepregs 3. Integration in tool 4. Thermoforming 5. Back injection moulding 6. Demoulding source: 14

13 Development projects Natural fiber based structural part Swinging stair pad Load-through device Engine carrier Battery carrier Door crash carrier 15

14 ZIM-development project Goal Development of weight reduction and stress-optimized hybrid structures made in the injection molding process suitable for series production Part Load-through device within the back seat of a SUV Quelle: Autozeitung Mounting situation: Back seat of a SUV Dimensions: 595 mm x 265 mm x 117 mm Weight: 3,85 kg; welded steel design HySpri: initial situation source: Brose 16

15 Load-through device Design of a new fiber reinforced plastic structure Topology optimization for load adapted rib design Appropriate design for polymer material FEM Simulation Structural analysis (strength and failure) with physical based and failure criteria Development of a series-production process Fully automated production chain Starting from prepreg cutting to the final part FRP structure Weight reduced load adapted structure Reduction of single components and process steps 17

16 Load-through device 18

17 ZIM-HySpri: Results Weight savings up to 55% compared to the conventional construction Reductions in the numbers of parts and production steps Proof of a mass production process chain from material cutting to molding of the part Steel: 3837g Welding construction with steel sheets lightweight structure: 1640g Thermoplastic prepreg with injection molded ribs Complex hybrid lightweight structure (UD-laminate structure) Complex hybrid lightweight structure (fabric reinforced) 19

18 Engine carrier Conception and design of a new FRP structure Topology optimization for load adapted rib design Integration of mounting parts Simulation und validation of the designed structure Material related strength analysis Failure Mode Concept according to Cuntze FRP structure Structural integration of the mounting parts Weight reduced and load adapted design Reduction of single parts 21

19 Door crash carrier Development of a Structural Health Monitoring System for a Door Crash Carrier in made from Fiber Reinforced Plastic Integration of textile based sensor system in the structure Change of the crash carrier from a steel design to a glass fiber composite design Processing of the part with injection molding and thermoforming process Crash carrier made from steel Textile reinforced top layers and back injected ribs 23

20 Door crash carrier Development of a Structural Health Monitoring System for a Door Crash Carrier in made from Fiber Reinforced Plastic Preheating of the thermoplastic prepreg Pick up of the nonwoven with integrated stitched sensor Thermoforming and back injection Placement in the mold for thermoforming 24

21 Door crash carrier Simulation and experimental verification of the chrash test Test mode: 3 point bending Surface layer on the compression side: thermoplastic prepreg (UD non crimped fabric PP with GF) Material for the back injected ribbs: PP-GF30 Static and dynamic test 25

22 Application transfer: System demonstrator CCC (Chemnitz Car Concept) D1 C1 C1 B1 D4 C5 B2 Silicon sensors Car seat shell Bottom pillar Platform VW up! Passenger Cell Design fuel cell system MERGE CCC Basic phase Application phase

23 Internationalization of MERGE Bydgoszcz CAMT + ICT Wrocław CXI, Liberec Technological approaches in tri-border region Germany, Poland and Czech Republic Flexible integral forming tools/molds Generative manufacturing Nano coating of fibers Availability of skilled employees/specialists International Master MERGE -10% weight billion t/a CO 2 Strengthening innovation and competitiveness through new lightweight solutions only 11 of 117 Clusters were successful in this German Government funded program. MERGE is the only one of all 43 Federal Clusters of Excellence, whose internationalization concept is funded in this way. 27

24 International Master s Programme: Merge Technologies for Resource Efficiency Study and do research in multi-national and transdisciplinary groups Students from all over the world With different scientific backgrounds For full-degree or short-term study Six profiles are available: Study profiles of the Masters Programme As a full degree Master student you choose one profile that fits to your Bachelor degree. 28

25 Thank you for your kind attention! Contact: Univ.-Prof. Dr.-Ing. habil. Hon.-Prof. Lothar Kroll Reichenhainer Str. 31/33 Phone: +49 (0) 371/ Room 104 Fax: +49 (0) 371/ Chemnitz Germany Coordinator Cluster of Excellence MERGE, TU Chemnitz Vice Dean for Research, International and Gender Equality of Faculty of Mechanical Engineering, TU Chemnitz Director of Institute of Lightweight Structures and affiliated institute Cetex Head of Fraunhofer Group STEX at IWU