Zero-waste composite parts production by an integrative approach of the UD and Crossply technology

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2 Zero-waste composite parts production by an integrative approach of the UD and Crossply technology 28 th annual international Sicomp conference 1 June 2017 Rien van den Aker

3 Van Wees

4 Van Wees develops, builds and commissions turnkey, machines for the production of composite materials and technical textiles mainly based on the UD and Crossply technology. Our mission is to be the leader in the UD and Crossply technology.

5 Evolution UD and Crossply Technology at Van Wees Foundation of BV machinefabriek van Wees Tilburg Management buy-in Rien van den Aker. Development and building of first 1,6 meter wide productionline for Israëlian customer. Dispersion based machine. UD and Crossply technology is core competence of van Wees. First thermoset prepreg machine is built and start thermoplastic composites development. Multi-axial UD Crossply machine development. Tailored blank and zero waste production solution.

6 Available equipment in Research & Technology Center Creels and UD 600 impregnation lines Tape slitting machine Crossply and tailored blanks machine Drumwinder Press

7 UD Technology

8 UD Technology UD is Uni-Directional: Material made from continuous fibers oriented in one direction and impregnated with a resin. UD material is the highest performing material in composites.

9 UD impregnation 1 Dispersion resin impregnation by kiss roller and post spreading. Very stable process with good impregnation, post melting of the polymers. Carbon PEEK laminate of 70 micron thickness

10 UD impregnation 2 Thermoplastic film impregnation, direct from polymer pellets by extruder, impregnation roller and post spreading. Cost effective process.

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12 UD tape production Typical speeds; Dispersion impregnation TP polymer film impregnation 10 20mtrs/min mtrs/min. Working widths mm

13 UD tape slitting UD tapes can be slit to narrow widths on cheese spools or on parallel wound spools.

14 Crossply Technology

15 Crossply Technology Crossply material: A laminate composed of at least two UD layers and assembled at an angle of 0 and 90 degree.

16 Crossply Technology Crossply material for thermoplastic composites are connected by spot welds. Welds are made using Van Wees elements with dedicated forms and material.

17 Composite tailored blank technology

18 Composite tailored blank technology Composite tailored blank: A composite panel which is composed of multiple layers and assembled at the UD tape angles which result in optimum performance of the product.

19 Multi-axial UD production UD tape Carbon PA6 300 mm wide. Connected by round spot welds. Multi-axial tape width 600 mm.

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21 Crossply and Multi-axial UD production Working widths mm. Typical speeds; Crossply production Multi-axial production 5 10 mtrs/min mtrs/min. Thermoplastic and thermoset UD tapes can be handled

22 Composite UD chips

23 Composite UD chips Residue from cutting blanks into shape. Dimensions and shape; 50 * 50 mm max. - irregular. Pressed panels have good formability and high performance.

24 Composite UD chips applications Lamborghini Huracan Aston Martin DB11.

25 Composite UD chips Teijin's Sereebo material. BMW, 7-series

26 Demonstrator crash beam for car door

27 Crashbeam for car door Based on the outcome of demonstration project Lipa series for making a crashbeam; 1 minute cycle time by injection molding. Original design; glass fabric PA6 - Organosheet, 3 mm thickness

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29 Plybook of the UD tapes tailored blank. Plybook: The composition of the panel with the number of UD tapes and its individual orientation. The composition is calculated with simulation software and dictated by the load on the product.

30 Patches and composites chips Patches are the most effective layer compositions of the plybook and connected by spot-welds. Chips are made and collected inline.

31 Crashbeam Glass PA cars; 2 million parts /year, Weight of tailored blank 395 gram, surface area 754 cm² 11 layers +45/135/0/0/0/90/0/0/0/135/45 Cutting loss; 30 %: resulting in mtr²/year of UD tape material to be made and converted into a tailored blank. Capacity should be tons/year.

32 Production line for tailored blanks UD tape production line. Composite tailored blank line.

33 UD line with creels.

34 Plybook crashbeam 11 layers +45/135/0/0/0/90/0/0/0/135/45 Patch 1 45/135/0/0 by mirroring patch 3 Patch 2 0/90/0 from Crossply machine Patch 3 0/0/135/45

35 Composite tailored blank line

36 Multi axial UD machine with inline cutting. Patch 1 and 3 production, 4 plies.

37 Crossply machine with additional 0 degree layer. Patch 2 production, 3 plies

38 Die cutting machine Well established method for cutting leather, plastics and foams Fast process, and automation solutions are present

39 Tailored blanks assembly and consolidation just in time with product forming Patches placement, consolidation and heating till placement in mould. Thicker products require more units, cycle time of the product is not influenced

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41 Patches assembly and consolidation 1. Patch 1 is taken from container 1 and placed in unit Patch 1 is heated till consolidation temperature in unit Patch 2 is taken from container 2, placed on top of patch 1, consolidating patch Patch 2 is heated, patch 1 is slowly cooling down. 5. Patch 3 placement, consolidating patch Patch 3 is heated and consolidated. 7. Tailored blank is released and heated till forming temperature and placed in press or injection molding machine

42 Patches assembly and consolidation with composite chips Instead of a UD tapes based patch, the composite chips are introduced. This results in a zero waste production solution.

43 Cost price calculations

44 Crashbeam Glass PA6 Investment in a turnkey line for making 2 million tailored blanks/year. UD line ,- Composite tailored blank line ,- Total ,- 3 shift production, 4 operators / shift, capacity is tons/year. Glass PA6 tailored blank cost 6,80 / kg

45 Crashbeam Carbon PA6 Investment is ,- 3 shift production, 4 operators/shift, capacity is 810 tons/year. Carbon PA6 tailored blank costs 17,30 /kg.

46 Crashbeam cost comparison Carbon PA6 Glass PA6 Part costs per car; including 30% waste material. Glass PA6 6,80 x 0,41 kg x 4 = 11,15 Carbon PA6 17,30- x 0,205 x 4 = 14,20 based on 50 % weight reduction of 850 grams. Weight reduction will cost 3,60 /kg

47 Crashbeam cost comparison Carbon PA6 Glass PA6 Part costs per car; no waste material. Glass PA6 6,40 x 0,41 kg x 4 = 10,50 Carbon PA6 14,70 x 0,205 x 4 = 12,05 based on 50 % weight reduction of 850 grams. Part cost reduction is 6% for Glass PA6 and 15% for Carbon PA6 Weight reduction cost is 1,80 /kg.

48 Conclusion

49 Conclusion High volume series production of composite parts needs a chain approach with material suppliers, machine builders, toolmakers and end users. Zero waste production of thermoplastic and thermoset composite parts is possible. Van Wees is happy to assist with product and process development in its Research and Technology Center.

50 Thanks, see you in Tilburg. Smart processes from tow to composites tailored blanks