Textile Production Technologies for Multi- Material-Lightweight Components
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1 Textile Production Technologies for Multi- Material-Lightweight Components JEC World 2017 Conference - Production Technology for Multi-Material Lightweight Components - Hans-Christian Früh RWTH, Peter Winandy
2 Textile Production Technologies for Multi-Material-Lightweight Components Outline Motivation Tailored Textiles the enabler of multimaterial designs Tailored NCF Open Reed Weaving Insert Integration using Laser Cutting Z-reinforcement with textile joining processes Multimaterial Joints Conclusion 2
3 New State of the art Motivation Considering multimaterial approach in early steps of composite process chains Increasing potential of light weight design and reduced production costs Modification of existing design and manufacturing route of multimaterial FRP parts Textile Production Preforming Consolidation Drilling Fastener Adhesive Rework Tailored NCF Production Preforming + Fastener Integration Consolidation Rework 3
4 Tailored Textiles - the enabler of multimaterial designs Application of Tailored Textiles Approach: application of Tailored Textiles Local adaption of textile properties Reinforcements - Fiber orientation - Fiber amount Insert or joint preparation of reinforcement textile Drapeability Near-net-shape Based on conventional textile production processes High process speeds High maturity level Tailored NCF [ITA] Open Reed Weaving [ITA] 4
![KCTECH [SGL] Local](/docs-images/90/104097725/images/5-2.jpg "reinforcements Adressing")
5 Tailored Textiles the enabler of multi material composite structures Tailored NCF [BMW] ITA and KCTECH [SGL] Local reinforcements Adressing joint or insert loads Adjusting warp knitting pattern as Process aid [ITA/KCTECH] 5
6 Tailored textiles the enabler of multi material composite structures Local reinforced woven textiles Feed of additional fibres only in certain needle areas Possibility of local reinforcements with additional fibre system Fabric pattern right side: Basic pattern: carbon fibre, 800 tex reinforcement: carbon fibre, 800 tex Feeding of up to 50 individual threads (carbon, 800 tex) in a multiaxial system Local reinforcement Basic weave 6
7 Improvement in material efficiency through tailored fabrics Reinforcement along the load path of the multimaterial component Experimental evaluation of potential for local reinforcements Different load cases Varying reinforcement geometry Comparison to different references 7
8 Fasteners for Multi Material Design applications Integration of fasteners Substitution of commercial components by composite parts Combination of different materials Detachable and standardized joints Fasteners [ITA] [ITA] [ITA] 10 mm [ITA] 8
9 Innovative LaserInsert-approach Ultra precise laser cutting of carbon fibre stacks Laser source Preform Ultra-short pulsed Laser ILT Insert Integration Laser processing Laser source Consolidation LUNOVU System integration Amphos ultra-short pulsed Laser source Insert Kohlhage Fasteners Innovative fasteners/inserts Preform ITA Preforming process Fixation unit 10 mm Schmalz Handling device 9
![Pull-out force [N] LaserInsert Benchmark](/docs-images/90/104097725/images/10-1.jpg "Innovative LaserInsert-approach Results")
10 Pull-out force [N] LaserInsert Benchmark Innovative LaserInsert-approach Results Reduced process times -> no drilling, adhesive preparation and application Higher part performance -> Increased pull-out forces for fasteners "Big Head" Aufgeklebt Onsert "Big Head" integriert "Kim" eingeklebt Integration under one layer Drilling and paste Variations Innovativer Insert Innovative process with laser processing 10
11 Improvement in mechanical properties by tufting Tufting in the production of sandwich panels Insert Top Layer Tufting Thread Robot Tufting unit Thread supply Sandwich Core Increase in z-axis properties (local reinforcement) Fixation of the Insert on-top of the textile or on the sandwich core Increase in insert-in-plane and out-of-plane mechanical properties Presser foot Thread Tufting needle Textile Tufting seam Up to 1000 Stiches per Minute 11
12 Joining using textile positive locking New shear connectors Surface modification of metal Small metal spines added Afterwards textile production technologies such as RTM No damage to textile structure Ductile cracking Adhesive bonding Form-fit joint FRC Metal Additional safety New shear connectors Hybrid joint: New shear connectors No fibre damage / ductile cracking 12
13 Joining multimaterial joints Increasing mechanical performances Surface modification of metal Shear connectors produced by welding process Shear stress capacity of 1 kn per connector For various metals: titanium, steel, aluminium Different geometries In combination with composites Increased stability Force transmission to inner layers Ductile post-cracking behavior High energy absorption Easy manufacturing process Hybrid joint: New shear connectors 1 mm Three shear connector designs: cylindric, pointed, round 13
![Force [N] Joining properties of new](/docs-images/90/104097725/images/14-1.jpg "multimaterial joints Higher maximum load New")
14 Force [N] Joining properties of new multimaterial joints Higher maximum load New multi stage breakdown Triple crash energy absorption 6 connectors 2 connectors No connectors 14 Displacement [mm]
15 Improvement in preforming efficiency through tailored fabrics Modification of existing design and manufacturing route of FRP parts Conventional product development process I II Requirement elicitation, definition of goals Conceptual part design Concept development based on tailored textiles III Preliminary laminate design 1 Technology pre-selection and preliminary design 2 Production oriented conceptual part design 3 Detailed reinforcement design IV Detailed laminate design 4 Economic and technical evaluation V Production planning Tailored textiles based subpreform concept 15
16 State of the art New Conclusion Textile production steps are the enabler for high performance multi material components Considering Tailored Textiles based concepts Enabling cost effective lightweight components Based on conventional textile production processes High process speeds High maturity level, robust manufacturing processes Tailored NCF Production Preforming + Fastener Integration Consolidation Rework Textile Production Prefroming Consolidation Drilling Fastener Adhesive Rework 16
17 Dipl.-Ing. Hans-Christian Früh Composites Division Institut für Textiltechnik der RWTH Aachen University Tel.: +49/(0)241/ Thank you for your kind attention! Our Partners: ITA TechnologieTransfer GmbH, Aachen Institut für Textiltechnik Augsburg ggmbh, Augsburg ITA Teknoloji Transfer Ltd. Sti., Bursa (Türkei)
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