Development of automated

Transcription

1 Development of automated composite research facility at UNSW Andrew Beehag a, Gangadhara Prusty b, Garth Pearce b, Jon Bradshaw, John Pearson c a Advanced Composite Structures Australia b University of New South Wales c Regional Development Australia Sydney

2 Introduction to authors Dr Andrew Beehag Operations Manager, ACS Australia General Manager, CRC ACS Prof. Ganga Prusty University of NSW John Bradshaw Industry Dev t Advocate Dr Garth Pearce University of NSW John Pearson Project Dev t Manager RDA Sydney

3 Background Funding secured to establish turnkey research and industry access facility in Australia Currently no turnkey industrial or research facility for automated composites manufacturing Facility will represent a unique opportunity to exemplify new high value manufacturing Specific focus on industry engagement

4 Why automation? Australia lagging in automated composites manufacturing No industrial or research facility for turnkey automated composites manufacturing (ATL, AFP) Estimate that 75% of composites manufacturing could be automated by 2020 Source: S.J. Peck, JEC Composites 2010 Genuine pathway to retaining high value manufacturing in Australia Source:

5 Case Study: National Composites Centre, Opened 24 November 2011 Funding Bristol 25m initial investment from Govt agencies Long term engagement gg from GKN Aerospace, Airbus, AgustaWestland, Rolls Royce and Vestas Automation, production and inspection facilities Twin robot tafp machine on 7m linear axis Hot drape forming system + laser projection Two autoclaves + hot press CNC prepreg & dry fabric fbi cutting Routers, waterjet cutter C scan, Omniscan, CT Scan, SEM and microscopes Source: composites centre/

6 Case Study: German Aerospace Centre Source: international.com/features/featuregermany wind industry birgit wieland german aerospace centre dlr/ featuregermany wind industry birgit wieland german aerospace centre dlr 2.html

7 UNSW Facility Collaboration Application for ARC LIEF grant Secured $500, funds Matches contributed funds of partners Funding for purchase and installation Partnership Brings together 8 universities + 1 Gov t research organisation Engagement of industrial partners Multiple disciplines Aerospace, civil engineering, maritime, renewable energy, automotive and more

8 Partners in Facility

9 Automated Tape Laying Wide tape Flat or gentle curvature ATL, AFP, TPP Automated Fibre Placement Multiple thin tapes/tows Complexandcurved objects Thermoplastic (Fibre/Tape) Placement Gas torch/laser heating Online placement and compaction Source: composites joins thermoplastic composites research centre/

10 UNSW Facility Robotic Manufacture Facility details to be determined Currently undertenderprocess Expected core facility Robotic fibre placement system Prepreg and dry fabric Additional facility (budget permitting) Thermoplastic composite placement head Integrated spindle Tape laying head

11 UNSW Facility Other complements major investment by UNSW Composites autoclave 1m dia x 15mlength 1.5m 500kN fatigue and multi axial testing machines Impact testing machine Water jet cutting $70 million laboratory refurbishment

12 Future Research: Aerospace Structures Australia behind world standard d ATL and AFP being demanded as production method Facility essential for continued Australian engagement in international research Source: eu/

13 Future Research: Renewable Energy Wind, water, tidal and more Automated manufacturing systems in development overseas Tailored solutions required for range of loads / environments Development for 20 + year lifetime Source: Leveraging additional facilities Underwater testing at Australian Maritime College Water impact testing facilities at Uni of Auckland Source: automated approach to blade manufacturing

14 Future Research: Pipeline Development High performance thermoset and thermoplastic composite pipes Integrated liners Spoolable / flexible systems Addressing a range of extreme temperature, pressure and chemical resistance challenges Source: Source: composite solution for deep oil and gas reserves part 1/

15 Future Research: Repair Systems Projected major growth area Tailored repairs for composite and metal aircraft, wind turbines and other structures High performance structures for pipeline repairs Infrastructure repair and capacity extension Ground transportation fatigue repair Mining infrastructure life extension Source: acs.com.au/index.php/contact us/12 main articles/technical articles/11 scarf repairs for aircraft structures, p// / p p/ / / / p pipeline repair system recognised at jec europe 2014 innovation awards/,

16 Future Industrial Innovation Assessing productivity improvements / reduction in manufacturing time Tailored reinforcement solutions Complex geometry layups Manufacturing with / around inserts Laminated layer aramid / metal / composite panels Development of sophisticated tooling solutions Alternative debulking technologies Press / drape / hydro forming of partial cure stage composite panels Extensionof of carbon filament winding to other than cylindrical components Automated fibre placement provides a consistent platform for assessing new manufacturing approaches

17 Facility operation Industry Engagement Research and industry engagement Low cost for access Development and prototyping Engagement ambitions Buildfuture industry in automated composites manufacture Build international competitiveness of composites industries in Australia Build new composites industries Build new composites industry cluster

18 Industry Engagement Mechanisms University based engagement UNSW or partner university Access to leading field experts, researchers and students Research and development of new composites applications Significant leverage available through industry linkage grants Industry based engagement ACS Australia is core participant in facility Engagement with ACS Australia Access to composites design/analysis/manufacturing experts Product development and prototype manufacture Potential to access international network (e.g. German Aerospace Center) for large scale prototype manufacture Development funding Both universities and ACS Australia can assist with grant applications

19 Composites Industry Cluster (NSW) NSW Govt has indicated increased support for composites industry 2013 Defence Position Paper 2013 Economic Framework Policy Sydney Aerospace and Defence Interest Group (SADIG) fostering establishment of Composites Cluster Interested businesses should contact / join SADIG Equivalent organisations outside Sydney are Hunter Defence and Shoalhaven Defence Discussions anticipated to form Cluster aimed at increasing defence manufacturing capabilitywithinnsw

20 University of NSW Contact Personnel Prof. Ganga Prusty ACS Australia Dr Andrew Beehag aus.com aus com Composites industry cluster (NSW) SADIG Jon Bradshaw dh h John Pearson Hunter Defence Ian Dick Shoalhaven Defence Megan Cleary megan.cleary@business.nsw.gov.au