Preform Technology for High Volume Manufacturing of Long Fiber Reinforced Structures

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1 Preform Technology for High Volume Manufacturing of Long Fiber Reinforced Structures LCC Symposium, Jaromir Ufer, Marco Göttinger, Dr. Lars Herbeck, September 12th 2014

2 Overview 1. CFRP in Automotive 2. Approaches of Voith Composites (Preforming) 3. The Voith Long-Fiber Preformer 4. Properties of Long-Fiber-Reinforced-Composites 5. Outlook Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 2

3 CFRP in Automotive Challenges of High Volume Manufacturing Quantity (> parts / year) Short cycle times (< 3 minutes) Reliable processes High automation level necessary Little waste (esp. little waste of fibers) [Roding Automobile] Recycling (waste, EoL-parts) Usually smaller and more complex parts compared to aviation ( established processes not utilizable) [BMW Group] Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 3

4 Approaches of Voith Composites 1/2 Section Preforming Mission: Development of specific processes and machines for automotive applications for preforming (EVA 60%) Goal: from roving to part (preform) Direct Fiber Placement Long Fibers Voith Long-Fiber Preformer (VLP) Continuous Fibers Voith Roving Applicator (VRA) Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 4

5 Approaches of Voith Composites 2/2 Section Preforming use of recycling-material Estimated comparison of Fiber Placement Processes Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 5

6 Voith Long-Fiber Preformer Realization Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 6

7 Voith Long-Fiber Preformer VLP Principle Direct processing of dry roving (or rcfstaple fibers) Continuous placement of fiber patches lateral to their fiber orientation No strength in the tape necessary and possible Great number of degrees of freedom Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 7

8 Voith Long-Fiber Preformer VLP Procedure VLP: 2D Layup Forming 3D Preform Near net-shape Defined / precise fiber orientation and thickness distribution Forming properties similar to deepdrawing materials complex shapes possible Combination with further processes (resin based) possible Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 8

9 Voith Long-Fiber Preformer VLP Prototype Robot based fiber-placement-head / stationary roving-coil unit Processing of the roving online in placement-head, current speed: 12 patches / second ( 6 kg/h) Controlling of the robot and fiber-placement-head with Siemens Sinumerik 840d (G-Code based) Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 9

10 Voith Long-Fiber Preformer VLP Testing Video VLP fiber placement Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 10

11 Voith Long-Fiber Preformer VLP Produced Fiber-Panels a) b) Cross section of single ply Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 11

12 Voith Long-Fiber Preformer VLP First Forming Trials Proof of possibility of deep-drawing and uniform material behavior Forming properties depending of binder and process Further trials ongoing Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 12

13 Voith Long-Fiber Preformer VLP Current Application MAI Pop demo-part with complex shape VLP sub-preform Testing of forming behavior and material properties Proof of joining with other subpreforms Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 13

14 Properties of Long-Fiber-Reinforced-Comp. Source: O. Meyer, Dissertation FPP Performance of perforated specimen Biaxial NCF 0 /90 //s FPP (load condition depending fiber architecture) 10 0 Tensile Modulus [GPa] NCF TFP Measurement of elongation during tensile testing 600 FPP Tensile Strength [MPa] Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 14

15 Summary Long-fiber-reinforced composites could gain 80-90% of the mechanical properties of continuous-fiber-structures VLP / FPP processes do enable a great number of degrees of freedom in fiber-distribution compared to classic preform methods Using this freedom, fiber structures with a higher performance than continuous-fiber-structures are possible VLP process is obtaining the capability of efficient manufacturing of long-fiber-preforms Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 15

16 Outlook Further testing (patch pattern, forming-behavior,...) VLP combined with other processes (hybrid preforming, e.g. VRA) Simulation of material forming behavior (R&D Project MAI Form) VLP fiber-placement rate [kg/h] Development of rcf staple fibers in MAI Recycling Trial of processing with VLP Design of serial machine 1 Prototyp (Status Quo) Prototyp* Serial machine* *) Estimation Voith Long-Fiber Preformer LCC Symposium 2014 Jaromir Ufer 16

17 Thanks to BMBF (F&E Project MAI Pop) Maximilian von Sommoggy und Erdödy Andreas Erhardsberger Mathias Hubald Prof. Drechsler & LCC