Braiding Technology: Machine Concepts, Processes and Applications

Size: px

Start display at page:

Download "Braiding Technology: Machine Concepts, Processes and Applications"

Lisa Barrett
6 years ago
Views:

1 Braiding Technology: Machine Concepts, Processes and Applications Prof. Klaus Drechsler JEC Conference March 2017 SGL Institute for Carbon Composites, TU München Fraunhofer IGCV, Augsburg

2 Overview 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

dimensional braiding [Sun, Science Direct, 2004] pull

3 The history of textile technologies for composites Ideas to improve interlaminar strength 3D braiding 3 dimensional braiding [Sun, Science Direct, 2004] pull unit mandrel 3D braiding machine [Guyader, 2013]

The history of textile technologies for composites 3D-stitching reinforcement Application: Attachement of dry stringers on fueslage skin, up to a length

4 The history of textile technologies for composites 3D-stitching reinforcement Application: Attachement of dry stringers on fueslage skin, up to a length of 12m and a thickness of 38mm with 3200 stitches per minute Computer-controlled Advanced Stitching Machine (ASM), developed by NASA and Boeing

(a) (b) 3D weaving looms for thick part manufacturing based on needle (a) and rapier

5 The history of textile technologies for composites 3D weaving Weaving loom producing 3D orthogonal woven fabrics [Mohamed / Zhang, 1992] 3D orthogonal fabric [Bilisik, 2009] (a) (b) 3D weaving looms for thick part manufacturing based on needle (a) and rapier (b) principles [King, 1977; Fukuta, 1974], production of 3D orthogonal fabrics

6 The history of textile technologies for composites Multiaxis 3D woven fabric Multiaxis pultruded rod fabric [Kimbara, 1991]; prototype stage Extension of lappet weaving; commercial stage Multiaxis weaving [Ruzand / Guenot, 1994]

7 The history of textile technologies for composites 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 Multiaxis weaving loom [Bryn / Nayfeh, 2004 / 2006]

8 The history of textile technologies for composites 3D circular weaving [Bilisik, 2000 / 2010] On the basis of 3D braiding principle Woven preform Weaving loom [Yasui, 1992]

$Fibre volume fraction Fibre material$

9 Conditions for High-Performance Composites Fibre length Fibre orientation L c D σ 2τ Q T Q T 1 T Fibre volume fraction Fibre material

10 costs Challenges for Automotive Applications Material Process - 50% Need for Action Rework - 90% - 70% Material Process Rework Up-todate Aim [MAICarbon] History, Status and Future - Potential Prof. Textile Dr.-Ing. Technologies Klaus Drechsler for High Performance Compoistes_Prof. 10

11 Direct and Indirect Preforming Process Chain Production of textile Weaving Warp Knitting Unstiched NCF Indirect Preforming Drapeing Pick & Drape Introduction of resin RoboMAG Direct Preforming FPP Braiding Dry Fibre Placement Infusion set-up CAD-based cutting Pick and Place/Drape Stacking & Assembling Direct Preform production Binder activation Self-adhesive Binder sewing

12 Indirect Preforming - Weaving - Warp Knitting - Stitched & Unstitched NCFs - Draping - Pick and Drape

13 Weaving Jacquard & ORW New machine technology 1. Jacquard-Weaving Multiaxial weaving 2. Open-Reed-Weave Partial reinforcement 3. Spread tow weaving reduced laminate thickness reduced crimp fewer voids Research topics Development of new 2/3D wovens Component development Generation of mechanical data Comparison of technologies Spreading

Warp Knitting _ Technology Stechkamm Zungennadel Lochnadel Warp knitting is a

possible by stitching with sewing threads no displacement with open constructions, no

knitting head: tubes, round nets, spacer fabrics Nadelbarre Wirkwerkzeuge mit 6

14 Warp Knitting _ Technology Stechkamm Zungennadel Lochnadel 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 Nadelbarre Wirkwerkzeuge mit 6 Legebarren Warp knit Modern warp knitting machine Warp knit with UD-carbon fibres and polyester stitching

Warp Knitting _ R & D Extrudable staircase

Highly elastic glass warp-knits Fine wire

15 Warp Knitting _ R & D 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 Hand rail Fine wire net Camouflage net Highly-elastic glass warp knit

16 Unstitched Non crimped Fabrics_ Folding / Winding + Evolution Revolution Revolution lighter safer recyling economical increase in efficiency Highly productive

17 Unstitched Non crimped Fabrics _ Folding / Winding Innovation: Folding / Winding procedure for non-crimped fabrics + high productivity: t/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

18 Direct Preforming - Compositence_RoboMAG - FPP - Braiding - Dry Fibre Placement

19 Braiding machines at Institut für Flugzeugbau IFB ; University of Stuttgart Radial Overbraiding machine 176 Bobbins Braiding machine for ropes 48 Bobbins Kuka-Robot for mandrel guiding Radial Overbraiding machine 64 bobbins

axis Braiding machine is provided by BMW Herzog braiding machine with 128 bobbins with 4/4 tying Radial bobbin arrangement Core

20 Braiding machines at Institute for Carbon Composites ; TU München Double ring braiding machine of Herzog with air extraction: 1 st ring: 60 bobbins 2 nd 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

21 Dry Fibre Placement Typical dry fiber placement cell (6 axis robot with 8 tow head) Dry fiber placement head with hot gas heater Dry fiber/binder yarn preform

22 Automation of preforming process _ Compositence Process Basic concept of the process innovation: Reduction of present complex preform production up to one process step Conventional Process - many individual processing steps

UMSETZUNG Automation of preforming process _

head tooling Fixation area Car wing Preform tooling

23 UMSETZUNG Automation of preforming process _ RoboMAG Roving feeding Fully automated layout of the preform directly from the dry fibre with maximum flexibility in fibre architecture Laying head tooling Fixation area Car wing Preform tooling layer 1 [e.g. 90 ] layer 2 [e.g. +45 ] layer 3 [e.g. -45 ]

architecture and wall thickness Use of all fibres, also hybrid Online quality assurance =

24 Automation of preforming process _ RoboMAG 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 = Compositence usage of raw material = additional consumption with conventional NCF Process

pieces (patches) patches are checked visually for tolerances robot

25 FPP- Fibre Patch Preforming 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

26 FPP- Fibre Patch Preforming Patch size: 60 x 20 mm Weights: 80 g/m² Patching rate: 1 Patch/s Performance: 720 cm²/min or 5.6 g/min

27 Assembling of Preforms - Combination of Technologies - Example: Roding and Airbus

28 Pick and Drape: Mechatronic Gripper systems

29 CAE- Chain and Simulation

30 Assembling, Tailoring and Combination of Technologies

31 Braiding Cell CTC Stade: Pilot machinery for aerospace stringers: BIAX-Braid 90 -winding UD-Braid Complex CFRP Stringers Fully automated braiding Appr. 1600m per Aeroplane Largescale production For A320-replacement =>40000 Stingers/year [EADS & SGL GROUP]

specific energy absorption: Composites: 60 100 kj/kg

32 Braided Crashboxes - Axialcrash Crashtubes for: passenger cars, trucks, train, helicopter, aircraft specific energy absorption: Composites: kj/kg iron/steel: ca. 15 kj/kg Aluminum: ca. 25 kj/kg

33 Combination of direct and indirect preforming - Roding

34 The path to high-volume applications: MCV - BMW i3 BMW 7 series - Konzeptstudie Megacity Vehicle Leichtbau Struktur Konzept (Quelle: BMW AG)

Fax: +49 (0)89 / 289-15097 Mail: info@lcc.mw.tum.

35 Institute for Carbon Composites Boltzmannstr Garching Germany Phone: +49 (0)89 / Fax: +49 (0)89 / Mail: info@lcc.mw.tum.de Web: Prof. Dr.-Ing. Klaus Drechsler

3D Fabrics for Composites

3D Fabrics for Composites Thomas Gries Institut für Textiltechnik der RWTH Aachen University, Aachen, Germany Benedikt Wendland, Timm Holtermann, Thomas Gries Contents Characteristics and types of 3D-textiles