High volume production of composite structures SICOMP Conference 2017-06-02 Jesper Eman Technology platform leader, jesper.eman@swerea.se 1
Weight saving potential [%] Drivers for light weight design in automotive Emissions from 130g/km (118) 2015 to 95 g/km in 2021 according to EU 1) 95g/km means a fuel consumption of 0.41l/10 km for petrol and 0.36 for diesel. The 2021 target represents a 40% reduction in comparison with the car fleet average of 158.7g/km 2007. Lightweight corridor Light Weight Corridor 10 /kg 2) CFRP Body with low productivity Lighter Hang-on parts (aluminum exterior) Tailored properties Higher strength Geometrical design 100kg weight reduction gives 20g CO 2 /km 3) State of the art Cost [ /kg] 1) https://ec.europa.eu/clima/policies/transport/vehicles/cars_en 2) Future Vehicle Body Concepts Dr. Stefan Kienzle 2017-02-15 3) Materials in Car Body Engineering Yoshio Akimune 2017-05-17 2
Specific properties Källa: www.grantadesign.com 3
Why not already used (more) in automotive? Cost, cost, cost Expensive raw material. Large efforts around the world to reduce cost Traditionally labour intensive manufacturing. This is where we focus! 4
Projects Effektiv produktion PAVE Samverkansprogram PRODKOMP2 Polymera kompositprod PRODKOMP PROSICOMP 2014 Triple Use 2015 2016 2017 2018 2019 ENAT ROBUST SALLSA MIMAP 5
Projects Effektiv produktion PAVE Samverkansprogram PRODKOMP2 Polymera kompositprod PRODKOMP PROSICOMP 2014 Triple Use 2015 2016 2017 2018 2019 ENAT ROBUST SALLSA MIMAP 6
ENAT ENAbling Technologies for high volume production Develop technologies and knowledge for high volume production with focus on automotive industry and pressing operations. Work packages: 1. Material waste recycling 2. Fast curing resins 3. Process simulations 4. Forming technologies 5. Cure cycle optimization 6. Automation 7. Process induced properties 8. Project management Budget: 1.6 MSEK year one Duration: 24 months 7
Material waste recycling Task leader: Magdalena Juntikka Objectives: Evaluate the possibilities to use uncured prepreg scrap to make carbon fibre moulding compounds Build a foundation for future research projects Outcome Tensile tests comparison between reference material (R) in the form of continuous textile reinforcement and scrap material (S) Results Modulus UD Scrap: Long ~85 GPa, Transv ~7 GPa Reference: Long ~108 Gpa, Transv ~7 GPa Modulus QI Scrap: ~33 GPa Reference: ~37 GPa Tensile strength UD Scrap: Long ~450 MPa, Transv ~30 MPa Reference: Long ~1430 MPa, Transv ~31 MPa Tensile strength QI Scrap: ~93 MPa Reference: ~466 MPa Concept development and research application on recycling manufacturing waste. 8 Presentation of Swerea SICOMP
Fast curing resins Task leader: Birgitha Nyström Objectives: State-of-the-art for fast curing resins/prepregs/smcs Evaluate the characteristics of selected materials Related projects: SALLSA, MIMAP Outcome State-of-the-art on fast curing resins, prepregs, SMCs Sortable database with data sheet information 9 Presentation of Swerea SICOMP
Cure cycle optimization Task leader: Erik Sandlund Objectives: Minimize time in pressing tool based on findings in the work package Fast curing resins. Related projects: PRODKOMP, PRODKOMP2 Outcome Method for minimizing time in press Prepregs tested yielding an OK result after less than 1 third of MRCC. Optimization of cure schedule is still ongoing. Several snap-curing materials are under development. OK Not OK 10 Presentation of Swerea SICOMP
Process simulations Task leader: Mohammad Rouhi Objectives: Road-map to clarify what process simulations (for high volume pressing operations) are critical and how these need to be developed. Related projects: SALLSA, PROSICOMP Outcome SOTA for process simulations of compression moulding Road map for the research area 11 Presentation of Swerea SICOMP
Forming technologies Task leader: Kurt Olofsson Objectives: Study and develop forming/pressing processes for carbon fibre SMC and continuous fibres. Related projects: PRODKOMP, PRODKOMP2 Outcome Concepts for sequential forming and methods to build hydrostatic pressure on resin Experiments carried out and analysed One internal invention application Student project to evaluate 3D preforming of roving Concept with best laminate quality Reference unflexible steel tool surfaces Preforms from roving 12 Presentation of Swerea SICOMP
Automation Task leader: Marie Jonsson Objectives: Develop technologies for the handling of the uncured composite material before the pressing operation. Possibly also demoulding Related projects: ROBUST Outcome Developed and tested two reconfigarable robot grippers for medium and large volume production Medium volume production Large volume production 13 Presentation of Swerea SICOMP
Process induced properties Task leader: Mohammad Rouhi Objectives: Investigate and evaluate methods used for dealing with the uncertainties in material properties that arise from the SMC-like manufacturing processes. Related projects: PAVE Outcome Review on analytical models for elastic properties and strength of short fibre composites 14 Presentation of Swerea SICOMP
Summary of outcome from ENAT 2016 Investigated properties of composites from recycled material Developed concept for recycling cut-off prepreg Project proposal within the area of recycling Mapping of existing snap-curing materials Methodology for rapid cure tests to optimize curing in press Evaluated two snap-curing prepregs with developed methodology Concept development and experimental study of innovative forming technology to accomplish sequential forming with maintained resin pressure. Internal invention application for one of the developed pressing concepts Student project where innovative preforming with roving has been evaluated experimentally Development of reconfigurable grippers State-of-the-art and road map for process simulation of moulding compounds Review of analytical models for process induced mechanical properties of short fiber composites More indirect outcome: PRODKOMP2 applied for and granted, focusing on high volume production of hybrid structures (SICOMP coordinator, tot. 8.9 MSEK) PROSICOMP applied for and granted, focusing on process simulation methodology for compression moulding (SICOMP coordinating, tot. 12.6 MSEK) Compression moulding as a part of an upcoming NFFP7 application. 15 Presentation of Swerea SICOMP
ENAT 2017 Budget 900 ksek Focus on demonstration and dissemination Three technical packages Demonstration of high speed curing in press with charge positioning and demoulding using gripper. Demonstration of sequential moulding on a non-flat tool Publication of comparison between highly controlled short fibre composite and models for elastic properties and strength. 16 Presentation of Swerea SICOMP
Project map
Process value chain Raw material SMC/ Prepreg Charge/ patch Press/ forming Trimming/ Water jet Quality control The PLS-250-2F equipment is designed for single step process of pre-preg making with utilizing hot melt resin systems. This process connecting the phases of the first stage of resin application on the transfer media (silicon paper) and the second stage impregnation of the fibers or fabrics with the resin film coated silicon paper and curing to the B-stage level. The main machine data and characteristics are the following: Max Width of Prepreg: up to 1500 mm Process speed: 0-5 m/min Process Temperature: 40-250 o C Heating Media: Thermal Oil Cooling Media: Water In the process of making prepreg, the plant usually use standard types of reinforcement material (carbon, glass and aramid). The plant is designed for producing pre-impregnating fibers with hot-melt resin in the following forms: Unidirectional prepreg (UD) Roving prepreg Fabric prepreg 18
19 Scientific Work for Industrial Use www.swerea.se