Center for Lightweight Composite Technologies. technology solutions for lightweight composites. A.Kadir Topuçar

Transcription

1 Center for Lightweight Composite Technologies technology solutions for lightweight composites A.Kadir Topuçar

2 Introduction Composites: 1+1 = 3 Thermoplastic solutions - Shortest cycle times - No recycling issues - Lower mechanics Thermoset solutions - Labour intensive process - Force orientated lay up possible - Highest potential for weight reduction

3 Thermoplastic fabrics prepregs fibre reinforced thermoplastic prepregs - fully impregnated and consolidated - thermoplastic matrix - Glass or carbon fibres

4 Thermoplastic fabrics Organomelt Process fully automated production of a thermoplastic composite structural part grabbing heating insertion closing injection demolding

5 Thermoplastic fabrics Organomelt heating

6 ENGEL composite technologies ir-oven

7 organomelt Brake pedal ZF

8 organomelt Process

9 Thermoplasticfabrics UD-Tapes Choosing UD-tapes Force orientated Optimized use of material - Building upoflayers - Preforming and backmolding E >> E ǁ ǁ

10 Reactive systems HP-RTM Process Thermoset composites High Pressure- Resin Transfer Molding Application for structural parts Optimized fiber orientation possible Good fiber impregnation insertion closure vacuum injection curing removing

11 Reactive systems HP-RTM HP-RTM reactive technology Material - Polyurethane systems (A: polyol, B: isocyanate) - Epoxy systems (A: resin, B: hardener) Circulation-position Mixing head - Recirculation of the components in the standard position - Cleaning-free output of residual materials into the mold Injection-position Source: Hennecke

12 Reactive systems HP-RTM For reactive technologies, Hennecke s high-pressure metering machine Streamline is fully integrated into ENGEL operating system CC-300.

13 Reactive systems Processing - thermosets

14 Reactive systems HP-RTM machine layout Henneckee Mixing head Mounted in mold ENGEL v-duo 400to 3600to Hennecke Streamline ENGEL CC-300 controls full process Automation linear- or multi axis robots

15 Reactive systems HP-RTM line layout C OMPETENCE IN COMPOSITES

16 In-situ anionic polymerisation caprolactam caprolactam and und activator C1 act. C2 cat. catalysator polyamide 6

17 ENGEL v-duo 700 Production unit

18 In situ theprocess In situ Carbon or glass fibres, fabrics are fed dry The fibresare impregnated with melted caprolactam, which then polymerizes into polyamide 6. Through injection moulding, the thermoplastic fibrecomposite part can then be further functionalized in a second mould.

19 In-situ-polymerisation & injection moulding Added values with combined processes! The fullythermoplasticpossibilityforhigh end composites! Load orientated design of fibre orientations Low pressure impregantion because ogf lowest viscosities High impact resistance with cast-nylon Optimum bondstrenghtbecauseofworkingin a one material system productionofa preform Reinforced structue madein insitu process C1 act. C2 cat. placing preform inside the mould Injection moulding of functinal elements

20 The best clamp unit for composites?

21 Machinery Organomelt machine layout ENGEL injection unit Automation ENGEL victory Conveyor belt -Oven atingtechnologybyengel Feed stock

22 Machinery Organomelt - Technology center BOND insert500 v/130 witheasixand2 x IRO

23 ENGEL v-duo Open Hybrid Lab Factory v-duo 3600 with 2 parallel injection units

24 ENGEL v-duo Concept ENGEL duo ENGEL v-duo machineson themarket Know-how in machine-concept Know-how in injection molding basedon two-platenconceptofduo same components useofgravity compatible with injection units

25 v-duo I A new concept for composite processing Optimized handling of inserts, because of vertical clamp system High accessability with sliding table Well proven, compact 2-platen-clamp system in new vertical design Energy saving drive system Optimized parts quality by parallelity controlled EXPERT-coining Clamping force sizes 400to / 700to / 1100to / 1700to / 2300to / 2700to / 3200to / 3600to

26 ENGEL v-duo University of Warwick v-duo 1700 with HP-RTM-unit Compression of prepregs and CF-SMC

27 ENGEL St. Valentin Compositess lab Hardware for R&D and Customer trials - v-duo 3550/ HD-RTM Streamline - V-duo 700 within-situ unit - Easix TX200L - Viper 12 preforming cell - IR-Oven - Chemical lab etc.

28 ENGEL St. Valentin lab application engineering hardware - ENGEL duo ENGEL duo1500 combi-m - ENGEL duo700 organomelt-tyr outs in proven horizontal-technology

29 Summary composites& injection moldingout ofonehand P-RTM on ENGEL v-duo 3600 IM on ENGEL duo4000 BMW, Leipzig ENGEL v-duo for BMW, Landshut

30 Center for Lightweight Composite Technologies Composite technologies need composite development! development