Page 3. How to produce a net shape Thermoplastic Composite part in one minute with the QSP

Transcription

1 Page 3 How to produce a net shape Thermoplastic Composite part in one minute with the QSP

2 Cetim the french innovation maker in mechanics 2 A regional, national and international player: 115 M turn over, 900 employees, 8 sites in France, 44,000 m² of laboratories and platforms 3 subsidiaries in France and North Africa Part of a strategic French R&D network: Covering all topics in the mechanical field with 9 open labs with universities Paving the way to innovative technologies on the whole product s lifecycle A strategy geared around innovation: R&T development & support for more than 4,000 customers per year Acting in standardization committees (216 seats)

3 3 Cetim Composite at a glance Cetim composite expertise and work Force Polymer Material expertise for 40 years +120 PhD, Engineers and Technicians 18M turn over in composite activity Scientific partnership with: ECNantes, ENSCachan, Onera, Imperial College of London Industrial partnership with AFPT for Spide TP and Pinette, Loiretech and Compose for QSP

4 QSD 4 Quilted Stratum Design for Part Design & Process Industrialization How to optimize weight reduction part on composite part / FEA simulation?

5 5 Exemple de reconception d une ferrure titane Adaptation des formes aux procédés composites : Tenue de objectifs en raideur et en dilatation thermique Réduction masse 20% Réduction coût 40% Support titane Interfaces fonctionnelles Design intermédiaires Support Composite

6 6 FEA SIMULATION - Cetim development : QSD OPTIM Quilted Stratum Design Optimization

7 Max constraint violation (%) 7 QSD Optim : Bi-level optimization stategy for multi-thickness lay up Level 1. Macroscopic optimization with homogenized material Research of optimal thickness distribution & stiffness distribution: - using the method of feasible directions implemented in Altair OptiStruct (FEA). - MATLAB program for automatic data implementation of Lamination Parameters Weight Number of iteration Objective = Min (weight) Number of plies (=Thickness) Best material = Isotropic An optimization with algorithms to choose the best shape and build the best plybook in partnership with Best material = orthotropic E 11 θ Level 2. Mesoscopic optimization with Stacking Sequence Table Practical design: laminates plybook MATLAB routine to evaluate the best Stacking Sequence Table Evaluation to choose according process recommandation Then Verification by FEA (Abaqus, Altair OptiStruct, ) Bending Stiffness Membrane Stiffness

8 8 Exemple de conception d un dossier de siège automobile Adaptation de l empilement à l objectif coût : Pas de pli continu Épaisseur variable Orientation optimale 1,5mm 2mm 3mm Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Fabric 0 /90 0,5mm Fabric 45 /-45 0,5mm Fabric 0 /90 0,5mm Fabric 0 /90 0,5mm Fabric 45 /-45 0,5mm Fabric 0 /90 0,5mm

9 Corrélation essais calculs 9 Identification inverse de comportement par corrélation calculs/essais Simulation des essais pour définir l instrumentation la plus adaptée

10 QSP 10 One minute multi-thickness layer preform assembly «From fibers to net shape part»

11 Quilted Stratum Process (QSP ) : A team success 11 Started in 2013 from concepts To a new pilot production line installed in 2015 And the product demonstration in 2016with the low cost composite bumper beam

12 Quilted Stratum Process (QSP ) : A new concept 12 Design optimized, the right material at the right place : Multi-thickness parts Multi-orientation parts Multi-material parts Netshape final parts for more added value : Global integration from raw material to final parts Low material scraps Assembly & functions integration Production performance : Full automated cell from preform assembly to netshape part Short cycle time (40 to 90sec) Competitive cost

13 13 General possibilities of the QSP THERMOFORMING & OVERMOULDING To add a maximum value intra-mold & get a netshape part RAW MATERIALS Fibers & Thermoplastic Any other organo sheets or tapes TP PULTRUSION To create semi-products with a low cost and high speed of production HIGH SPEED CUTTING To cut all patches needed for the multi-thickness preform HIGH SPEED TRANSFER < 5sec PREFORM ASSEMBLY To make an automated assembly of a multilayer netshape preform < 1min FAST HEATING Combining conduction & High-Speed IR ovens for multi-thickness preforms

14 Pultrusion thermoplastic Cost /kg 14 Production performance : Production speed : From 1 to 5 m / min Competitive cost Speed = the key parameter Cost /kg Tape width = 100mm Target 2017 Thickness 0,5 mm 1 mm 1,5 mm 2 mm Tape width = 200mm Target 2017 Thickness 0,5 mm 1 mm 1,5 mm 2 mm Pultrusion Speed : m/min Pultrusion Speed : m/min Quality of tapes : Glass fibers from 45 to 55% of volume Carbon fibers from 60 to 70% of volume Matrix layer on surface (improve the inter-tape welding) Low porosity rate < 2,5% 1mm

15 Cutting machine 15 Flexible technology : 2D straight or curve cutting Thickness from 0,15 to 5mm Sheet maxi 1300 x 950mm Rolls up to 315mm width High-speed technology : Cutting speed up to 500mm/sec Example for a UD Glass fiber - PA6 : 1,5mm thickness cut in one way Speed = 400mm/sec Cutting quality : Clean technology no dust, no water Limited burr Cost : 0,01 to 0,05 / 100mm cut

16 Preform assembly machine 16 Production performance : From cut patchs to final preform Full automated cell in line with press Short cycle time < 60sec Flexibility of the machine : Size 1300 x 950mm 8 layers & 4 tapes / layer Example on QSP multithickness part : 8 layers / 13 patchs Thickness from 2,5mm to 3,5mm Multi material preform Multi-orientation preform Preform assembly < 60sec Example of QSP multi-thickness part :

17 Heating process Temperature ( C) Transfer High-speed transfer = 5sec 17 Production performance : Robust technology combination Heating technology with patented specifications Short cycle time to heat multithickness preforms Example on QSP part = 50sec Allows cycle time close to 60sec Quality / preforms heated : Reduction of oxidation on PA Humidity PA after heating process < 0,2% (mass) : Even if saturation before Thermography after heating : +/- 15 C observed PA6GFmultithickness part (from 2,5mm to 3,5mm) Classic temperature evolution / process QSP Material = PA6 - Glass Fiber / Thickness min = 2,5mm, max = 3,5mm Surface 3,5mm Pre-heating - conduction = 46sec Time (s) Final heating - IR = 50sec

18 High speed transfer with robot 18 Production performance : High speed transfer : < 5sec after heating / press closed A minimum temperature loss during transfer : 15 C lost during transfer between IR oven and press on QSP part example Flexibility of the machine : Specific gripping hands available High resistance temperature needles High resistance temperature vacuum systems Preforming during transfer possible with gripping hands

19 Forming netshape 19 Production performance : From cut patchs to final preform Full automated cell in line with press Short cycle time < 90sec Capacity of the press : 500T vertical press Krauss Maffei injection unit Roctool generator 200kW Tooling expertise Ex: Preform removal system / mold Partner :

20 QSP 20 Ready for direct assembly How to produce net shape part / No machining operation added? In mold process insert assembly

21 σn/σ0 Assembly & function integration in-mold 21 Creation of holes one-shot during the forming process More added value with a minimum cost No waste of material, re-use for reinforcement A minimum damage on fibers to increase mechanical performances Values of tensile strength (compared to complete part without hole) : 0,80 0,70 0,60 0,50 0,40 0,30 0,20 0,10 - drilling after forming one shot hole without compacting one shot hole with compacting

22 Assembly & function integration in-mold 22 After molding technology to integrate thread in composite part : Hole creation intra-mold + BOLLHOFF RIVKLE SFC setting Insertion of RIVKLE SFC Smart For Composite - BOLLHOFF Suppression of radial stresses Axial stresses only Stresses uniformly distributed on a ring Distance to edge reduced Provides a greater hole tolerance

23 Force (N) Assembly & function integration in-mold Force (N) Allongement (mm) In molding technology to integrate thread in composite part : Overmolding insert during forming process Direct insertion of IMTEC (Böllhoff) through the composite, with one shot overmolding A maximum added value with a minimum cost & final part ready for assembly High strength and energy absorption Drilling after forming + RIVKLE SFC M6 Pull through results on PA6GF, thickness 1,5mm One shot hole compacted + RIVKLE SFC M6 IMTEC insertion one shot (no hole before) + overmolding

24 24 QSP The low cost composite bumper beam

25 25 From metal to multi materials

26 Masse Conception:Méthodologie Quilted Stratum Design 26 Itérations

27 Simulations: 27 Patchs de renforcement Simulation du formage Identification zones critique formage Optimisation forme netshape Simulation des scénarios de crash Vérification des critères d absorption d énergie Loi de comportement du composite en crash Chainage numérique : Position des patchs Orientation des fibres Choc bumper

28 Industrialisation: outillage de thermo-estampage 28 Fabrication d une pièce «net-shape» formage + surmoulage Réalisation de perçages «one-shot» intra-moule

29 Fabrication Quilted Stratum Process 29 Opérations: Pultrusion Découpe Nappage Formage Temps de cycle = 120 sec Contrôle IR en ligne:

30 30 Poutre de parechoc Résultats Résultats : 2 scénarios de crash validés sur 3 Réduction de masse de 28% Cout série pièce composite 10 Cadence validée = p/an Perspectives du projet Optimisation pour valider le dernier scénario crash Validation TRL 6 Proposition aux constructeurs par Mise en place de QSP série par

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