Procomp project: thermoplastic composites technology Società: Proplast Speaker: Andrea Romeo - Head of Engineering Dept Users Meeting Italia

Transcription

1 Procomp project: thermoplastic composites technology Società: Proplast Speaker: Andrea Romeo - Head of Engineering Dept 2016 Users Meeting Italia

2 Procomp: Thermoplastic composite technology One-step processing Highly structural components Design freedom of injection moulded features Termoplastic/ continuous fiber composite

3 Procomp: Thermoplastic composite technology Omega-shaped composite bone by in-mould thermoforming Thermoplastic laminate (PP/continuous glass fibers) Ribs / bosses / snaps Overmoulding of thermoplastic PP+30% gf

4 Equipment

5 Process steps Laminate heating By IR-lamp oven Glass fiber Twill 50/50 fabric PP matrix Thickness = 1 mm T laminate after heating = C Laminate transfer Pick-up from oven Fast movement Extraction of previous part from mould Placing pre-heated laminate

6 Process steps Mould closing/laminate thermoforming One-step forming By mould clamping (cavity/core) Thermoplastic injection overmoulding PP+30% gf(borealis GD301FE black)

7 Laminate retaining system To hold the laminate for thermoforming By means of pins Mold features

8 Laminate retaining system To hold the laminate for thermoforming By means of pins Mold features

9 Mold features Injection system Hot runner injection system Thermoplay FNH Injection directly on part On longitudinal flow leader (supporting partners LOGOS) 4 holes for flow transfer to inner side INJECTION

10 Mold features Injection system Hot runner injection system Thermoplay FNH Internal flow leader to distribute material to periphery and fill ribs INJECTION

11 Mold features IN 2 IN 1 IN 3 Cooling system IN 4

12 Material choices

13 Materials ORGANOSHEETS PP+GF 50/50 (Twill fabric) TEPEX dynalite 104-RG600(2)/47% Thickness = 1 mm PP+FV 80/20 (Almost unidirectional) TEPEX dynalite 104-RGUD600(2)/47% Thickness = 1 mm OVEROULDING THERMOPLASTIC PP+30%FV Xmod GD301FE

14 Testing Flexural testing 3 (points bending) Supports span: 150 mm Testing speed: 2 mm/min

15 Response PP+30%gf (no laminate) 50/50 twill laminate + overmoulding Load(kN) 80/20 unidirectionllaminate + overmoulding Displacement(mm) Material σ fm ε fm kn mm PP+30%gf (no laminate) /50 twill laminate + overmoulding /20 unidir laminate + overmoulding

16 Overmoulding simulations

17 Filling pattern TP composite overmoulding simulation Balanced filling

18 Complete filling TP composite overmoulding simulation Thermoplastic laminate composite Thermoplastic injection overmoulding

19 Temperature atflow front TP composite overmoulding simulation Flow front temperature under control No overheating during filling No relevant temperature drop

20 Packing phase TP composite overmoulding simulation Efficient packing Regular pressure drop over flow lenght

21 Frozenlayeratend of packing TP composite overmoulding simulation Partial freezing at end of packing Chance to extend packing time

22 Temperature atend of cooling TP composite overmoulding simulation Long enough cooling time Average part temperature under reference ejection temperature (90 C)

23 Warpage TP composite overmoulding simulation x-direction y-direction z-direction Limited warpage in x directions. Symmetrical deformation. Relevant warpage in y and z direction Mucell foaming injection moulding (to reduce warpage)

24 Mucellfoaming injection moulding Key points 1. Reduced viscosity of molten thermoplastics 2. Microcellular structure of thermoplastic moulded parts

25 Mucellfoaming injection moulding Injection starts Partial volumetric filling In cavity gas expansion 3. Nucleation and growth of cells depends on pressure during injection 4. Growth goes on until material freezes time

26 Mucellfoaming injection moulding 5. Expansion capability of gas is affected by part thickness 6. Foaming level depends on flow length (see chart) Weight reduction [%] Weight reduction (%) Low viscous (PA) top Flow Factor factor % Wt. Reduction envelop as a function of flow factor High viscous (PC+30 gf)

27 Mucellfoaming injection moulding 7. Foaming is controlled and repeatable 8. Mechanical properties are preserved up to expansion about 10% impact strength tensile strength flexural strength Celanex 2300 GV 1/30 (PBT with 30 % glass) Source: Ticona GmbH

28 Mucellfoaming injection moulding 9. Mechanical properties variation depends on the plastic material itself 10. Mechanical properties variation depends on fillers/reinforcement Unfilled Filled

29 Expansion prediction Mucellfoaming injection moulding Cells size Cells density Good foaming properties Cells size under 50µm Cells density well distributed

30 Expansion prediction Mucellfoaming injection moulding Good foaming properties Completed gas foaming (cells growth finished) Overall weight reduction 8.4% Cells density

31 Temperature atend of cooling Mucellfoaming injection moulding Faster cooling Average part temperature lower than compact mouldingand largely below reference ejection temperature (90 C)

32 Warpage Mucellfoaming injection moulding x-direction y-direction z-direction By Mucell process: Strong reduction of warpage in all directions. Symmetrical deformation. Planarity largely recovered

33 Mucell virtual cycle TP composite overmoulding simulation Mucell Compact t inj (s) T melt ( C) T mould ( C) Gas dosage (%) 1 -- Switchover (%) t holding (s) 1 9 P holding (bar) t cooling (s) t cycle (s) Shot weight (g) x-warpage (mm) / / y-warpage (mm) / / z-warpage (mm) / / Variation (%) / / / -85

34 FEM simulations

35 Virtual run Process Material Structure Simulating the process Conventional moulding Mucell injection moulding Heat and cool injection moulding Prevision of the Microstructure Fiber orientation Cell dimensions Cell density and distribution Building the material model Accurate Mechanical model sensitive to morphology Structural simulation Stiffness Strength Performance

36 FEM simulation of thermoplastic composites Procomp Laminate modeling(exahedral mesh) Overmoulding modeling(tetrahedral mesh) Laminate: Twill 50/50 glass, PP matrix Overmoulding: PP+30%gf (Borealis GD 301FE) Mirostructure description + Microstructure overall response Materialmodel sensitive to microstructure FEM

37 FEM simulation of thermoplastic composites

38 FEM simulation of thermoplastic composites Simulation vs experimental

39 FEM simulation of thermoplastic composites

40 FEM simulation of thermoplastic composites Crack initiation

41 FEM simulation of thermoplastic composites 1,2 Procomp Twill 50/50 PP+30%gf 1 0,8 Standard force [kn] 0,6 0,4 0, ,2 Deformation [mm] Experimental Simulation

42 Sum up

43 Thermoplastic composites Favourablecombination of reinforce by continuous fibers (fabric) characteristic of traditional thermoset composites and chance to integrate on parts features typical of injection moulding High stiffness High mechanical strength Excellent impact resistance Lightweight Chemical resistance Processability Production process of high productivity Production cycle similar to injection moulded thermoplastics Unlike Thermosets, no long curing times are required NO need of autoclave neither specific process devices Completely automated process

44 Design freedom / integration of functions Chance to integrate functional details by overmoulding(ribs, bosses, pins, anchor points, snap-fits etc.) Unlike hi-filled thermoplastics, exhibit progressive damage and progressive failure No sudden failure Simulations of thermoplastic composites Simulation on injection overmoulding Compact/Mucellsimulation Prediction of process and part quality Local prediction of overmoulded component s morphology (fiber orientation, cells size and density) Exploitation of flow simulation results into FEM structural simulations Integration of process-dependent morphology into FEM structural simulations Material model sensitive to microstructure of both laminate and overmoulding Advanced structural simulations Highest correlation between virtual modeling and reality

45 Thank you for your attention Andrea Romeo Consorzio Proplast Head of Engineering Dept

46 Sezione

47 Il problema 47

48 La soluzione 48

49 I Vantaggi 49

50 Thank You