Prof. Klaus Drechsler SGL Institute for Carbon Composites, TU München Fraunhofer IGCV, Augsburg Braiding Technology: Machine Concepts, Processes and Applications JEC Conference March 2017
Prof. Klaus Drechsler
SGL Institute for Carbon Composites, TU München
Fraunhofer IGCV, Augsburg
Braiding Technology: Machine Concepts, Processes and Applications
JEC Conference
March 2017
• History of braiding and other textile technologies
• Requirements for high performance composites
• In-direct preforming technologies
• Direct preforming technologies
• Exemplary applications of braiding technologies
• Future challenges
Overview
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Drechsler_Leuven 09/2013
Ideas to improve interlaminar strength
• 3D braiding
The history of textile technologies for composites
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3 dimensional braiding [Sun, Science Direct, 2004]
mandrel
pull unit
3D braiding machine [Guyader, 2013]
• 3D-stitching reinforcement
The history of textile technologies for composites
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Computer-controlled „Advanced Stitching Machine (ASM)“, developed by NASA and Boeing
Application:Attachement of dry stringers on fueslage skin, upto a length of 12m and a thickness of 38mm with3200 stitches per minute
• 3D weaving
The history of textile technologies for composites
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3D weaving looms for thick part manufacturing based on needle (a) and rapier (b) principles[King, 1977; Fukuta, 1974], production of 3D orthogonal fabrics
(a) (b)
Weaving loom producing 3D orthogonal wovenfabrics [Mohamed / Zhang, 1992]
3D orthogonal fabric [Bilisik, 2009]
• Multiaxis 3D woven fabric• Multiaxis pultruded rod fabric [Kimbara, 1991]; prototype stage
• Extension of lappet weaving; commercial stage
The history of textile technologies for composites
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Multiaxis weaving [Ruzand / Guenot, 1994]
• Multiaxis 3D woven fabric• Multiaxis 3D weaving [Mohamed / Bilisik, 1995 / 2010]; prototype stage
• Modified 3D lattice weaving [Khokar, 2002]; prototype stage
• Multilayer narrow weaving principle; prototype stage
• Application: structures as connector to structural elemensts of aircraft components
The history of textile technologies for composites
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Multiaxis weaving loom [Bryn / Nayfeh, 2004 / 2006]
• 3D circular weaving [Bilisik, 2000 / 2010]• On the basis of 3D braiding principle
The history of textile technologies for composites
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Woven preform Weaving loom [Yasui, 1992]
Conditions for High-Performance Composites
Fibre materialFibre volume fraction
Fibre length
2τ
σDLc
Fibre orientation
1
T TQTQ
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Challenges for Automotive Applications
Rework
Process
Material
Rework
Process
Material
co
sts
Up-to-
date
Aim
- 50%
- 90%
- 70%
Need for Action
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[MAICarbon]
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Direct and Indirect Preforming – Process Chain
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Production of textile
CAD-based cutting
Stacking & Assembling
Infusion set-up
Introduction of resin
Binder activation sewing
Pick and Place/Drape
WeavingWarp KnittingUnstiched NCF
Direct Preform production
DrapeingPick & Drape
RoboMAGFPP
BraidingDry Fibre Placement
Indirect Preforming Direct Preforming
Self-adhesive Binder
- Weaving
- Warp Knitting
- Stitched & Unstitched NCFs
- Draping
- Pick and Drape
Indirect Preforming
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• New machine technology
Weaving – Jacquard & ORW
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reduced laminate thicknessreduced crimpfewer voids
Research topicsDevelopment of new 2/3D wovensComponent developmentGeneration of mechanical dataComparison of technologiesSpreading
3. Spread tow weaving
Multiaxial weaving Partial reinforcement
2. Open-Reed-Weave1. Jacquard-Weaving
Wirkwerkzeuge mit 6 Legebarren
Nadelbarre
Stechkamm
Zungen-nadel
Loch-nadel
Modern warp knitting machine
• Warp knitting is a loop-forming technique• Up to 50 fibres on one needle• woven fabric like structures possible by stitching with sewing
threads• no displacement with open constructions, no fraying edges,
even elongation of the structure• Warp knitting machines with double knitting head: tubes, round
nets, spacer fabrics
Warp knit with UD-carbon fibres and polyester stitching
Warp knit
Warp Knitting _ Technology
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➢ Extrudable staircase hand rails
➢ Energy absorptive 3D-warp-knits
➢ Highly elastic glass warp-knits
➢ Fine wire nets for space antenna reflectors (30µm) and shielding
➢ Low voltage heating with metal and carbon
➢ Camouflage nets against IR and radar
Warp Knitting _ R & D
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Fine wire net
Highly-elastic glass warp knit
Hand rail
Camouflage net
Unstitched Non crimped Fabrics_ Folding / Winding
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Revolution Revolution
+
Evolution
economicalincrease in efficiency
Highly productive
lightersafer
recyling
Unstitched Non crimped Fabrics _ Folding / Winding
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Innovation: Folding / Winding procedure for non-crimped fabrics
+ high productivity: 200 – 600t/a
+ low investment for machinery
Machinery concept:
• Folding and winding of UD-Tapes around a conveyor belt system
• Forming of lateral directed, one-layer UD-tapes with a folding process
• Pressing of the wound UD-tapes with a double calander
• Pull-off of the MD and winding onto a roll
- Compositence_RoboMAG
- FPP
- Braiding
- Dry Fibre Placement
Direct Preforming
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Braiding machines at
Institut für Flugzeugbau IFB ; University of Stuttgart
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Radial
Overbraiding
machine
176 Bobbins
Radial
Overbraiding
machine
64 bobbins
Braiding
machine for
ropes
48 Bobbins
Kuka-Robot
for mandrel
guiding
Braiding machines at
Institute for Carbon Composites ; TU München
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• Double ring braiding machine of Herzog with air extraction:
• 1st ring: 60 bobbins
• 2nd ring: 84 bobbins
• 2 gates for filler threads
• Axial bobbin arrangement
• Core guidance by one robot on a linear axis
• Braiding machine is provided by BMW
• Herzog braiding machine with 128 bobbins with 4/4 tying
• Radial bobbin arrangement
• Core guidance by two robots on linear axis
• Pivoted for horizontal and vertical braiding
• Possibility of retooling for flat braids
Dry Fibre Placement
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Dry fiber placement head with hot gas heater Dry fiber/binder yarn preform
Typical dry fiber placement cell (6 axis robot with 8 tow head)
Automation of preforming process _ Compositence Process
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Basic concept of the process innovation:Reduction of present complex preform production up to one process step
Conventional Process -many individual processing steps
Automation of preforming process _ RoboMAG
tooling layer 1 [e.g. 90°] layer 2 [e.g. +45°] layer 3 [e.g. -45°]
UMSETZUNG
tooling
Laying head
Fixation area
Roving feeding
Car wing Preform
Fully automated layout of the preform directly from the dry fibre with maximum flexibility in fibre architecture
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Advantages:
• Production of Preform in one step
• Fully automated
• Production directly from the fibre
• Minimal cutting waste
• Freely designable fibre architecture and wall thickness
• Use of all fibres, also hybrid
• Online quality assurance
Automation of preforming process _ RoboMAG
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= Compositence usage of raw material
= additional consumption with conventional
NCF Process
FPP- Fibre Patch Preforming
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• Procedure : • spread and bindered roving band is stored on a roll• system cuts the roving band in defined long pieces (patches)• patches are checked visually for tolerances• robot picks up the patches and places them to a defined form
SOWEMA
FPP- Fibre Patch Preforming
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Patch size: 60 x 20 mmWeights: 80 g/m²Patching rate: 1 Patch/sPerformance: 720 cm²/min or 5.6 g/min
- Combination of Technologies
- Example: Roding and Airbus
Assembling of Preforms
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Pick and Drape: Mechatronic Gripper systems 2010-2015
History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof. Drechsler_Leuven 09/2013
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CAE- Chain and Simulation
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Assembling, Tailoring and Combination of Technologies
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Braiding Cell
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CTC Stade: Pilot machinery for aerospace stringers:
• Complex CFRP Stringers• Fully automated braiding
• Appr. 1600m per Aeroplane „Large-scale production“
• For A320-replacement =>40000 Stingers/year
[EADS & SGL GROUP]
BIAX-Braid 90°-winding UD-Braid
Crashtubes for:passenger cars, trucks,train, helicopter,aircraft
specific energy absorption:Composites: 60 – 100 kJ/kg iron/steel: ca. 15 kJ/kgAluminum: ca. 25 kJ/kg
Braided Crashboxes - Axialcrash
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Combination of direct and indirect preforming - Roding
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The path to high-volume applications: MCV - BMW i3 – BMW 7 series - …
• Konzeptstudie – Megacity Vehicle • Leichtbau Struktur Konzept
(Quelle: BMW AG)
History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof. Drechsler_Leuven 09/2013
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History, Status and Future - Potential of Textile Technologies for High Performance Compoistes_Prof. Drechsler_Leuven 09/2013
19.09.2013
Institute for Carbon Composites
Boltzmannstr. 1585748 GarchingGermany
Phone: +49 (0)89 / 289-15092Fax: +49 (0)89 / 289-15097
Mail: [email protected]: www.lcc.mw.tum.de
Prof. Dr.-Ing. Klaus Drechsler