006 fkv applications 1 ws0708
TRANSCRIPT
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Kindervater FKV_2007_2008_Applications Applications-1: 1
Anwendungen von FVW (Teil1)
Christof Kindervater
Vorlesung WS 2007/2008DLR Stuttgart, Institut für Bauweisen- und
Konstruktionsforschung
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Kindervater FKV_2007_2008_Applications Applications-1: 2
Polymer Composite Applications
• Aeronautics- sailplanes- man powered light aircraft, ultra-lights
- light single engine aircraft- propellers- military aircraft- transport civil aircraft- helicopters
• Space applications- antennas- satellite structures- pressure vessels- parabolic antennas- platforms for optical equipment andmeasurement set ups
• Energy technology- wind turbine rotor blades- wind tunnel fans
•Sporting equipment
• Ship building
•Vehicle Technology- cars, trucks, racing cars, motorbikes- trains
• Civil engineering
•Medicine technology
•Mechanical engineering,plants/facilities
• Electro technical applications,electronics
•Other applications
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Kindervater FKV_2007_2008_Applications Applications-1: 3
Aeronautical composite applications
• General topics
- wide applications of polymer composites
- advantages compared to metals:> weight reduction due to high specific strength and stiffness> less weight results in higher performance and lower
operational costs
> less single parts due to integral design which results in lessassemblage costs
> longer life time due to high fatigue performance> realisation of high quality aerodynamic surfaces
- structural design comprise monolithic stringer stiffened andsandwich shells andpanels, sandwich design with foam cores and paper oraluminium honeycombs
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Kindervater FKV_2007_2008_Applications Applications-1: 4
Aeronautical composite applications
Sailplanes
• series application since 1957
• use of glass, carbon and aramid fibres and fabrics
• application of epoxy matrices
• hand lay-up manufacturing
• use of vacuum assisted resin infusion and low pressureprepregs are increasing
• high design flexibility
• German sailplane manufactures provide 90% of theworld production
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Kindervater FKV_2007_2008_Applications Applications-1: 5
High performance sail planes
Phönix Akaflieg Stuttgart (1954)• First composite sailplane in series
production
• glass fibre/balsa sandwich
FS-29 Akaflieg Stuttgart 1976
CFRP telescope wing 13 - 19 m
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Kindervater FKV_2007_2008_Applications Applications-1: 6
High performance sailplanes and ultra-lights
Nimbus 4 Schempp/Hirth
1994 (CFRP/GFRP)
wing span: 26 m, empty weight: 470 kg
Musculair 1
• Spannweite: ca. 20 m
• Leergewicht: ca. 28 kg
• Zuladung: ca. 84 kg
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Kindervater FKV_2007_2008_Applications Applications-1: 7
Aeronautical composite applications cont´d
Man powered ultra-light aircraft
realisation of extreme light designs, especially CFRP and aramidfibres and fabrics
Single engine light aircraft and commuter type aircraft
applications of composites in series production since 10 years
high aerodynamic quality comparable to sailplanes
use of GFRP and CFRP in primary structures, aramid fabrics in
secondary structures like fairings
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Kindervater FKV_2007_2008_Applications Applications-1: 8
Light single engine aircraft
BL 11-KEA (Bernd and Lucia Hinz)
• design GFRP sandwich (foam core)
• rudder: CFRP-Nomex
• wing span: 10 m (12m²)
• fuselage: 6.75 m
• empty weight: 440 kg/MTOW:720kg
FFT SC 01 B-160 Speed Canard
• wing span: 8 m (10,7 m²), one spar,
GFRP/CFRP-sandwich
• Fuselage: 7,12 m, GFRP monolithic shell
• empty weight: 630 kg, MTO: 820
•Vcr : 343 km/h
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Kindervater FKV_2007_2008_Applications Applications-1: 9
Icaré 2 - solar powered motor glider
Winner of Berblinger Award of the City of Ulm 1996
• Designed and fabricated by the Aeronautical faculty
of the University of Stuttgart
• wing span 25 m (25,7 m2), carbon and carbon foam
sandwich laminates
• MTOW: 360 kg
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Kindervater FKV_2007_2008_Applications Applications-1: 10
Solar Impulse
• Ultraleichte Struktur
• Spannweite: 80 m
• Ultra dünne und flexible Solarzellen
-60°C - +80°C
UV resistent
• Flughöhe: 12.000 m
• Weltumrundung: 1 Stop auf jedemKontinent
Title: SOLAR IMPULSE
Description: Solar airplane
Copyright SOLAR IMPULSE/EPFL –
Artist: Claudio Leonardi
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Kindervater FKV_2007_2008_Applications Applications-1: 11
Die Brennstoffzelle hebt ab – HyFish
• Spannweite 1,5 m
• Vcruise: 200 -300 km/h
• Flughöhe: bis 7000 m
• Anwendung: UAV, Atmosphärenforschung
Brennstoffzelle
Sauerstofftank
WasserstofftankQuelle: DLR, SmartFish GmbH
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Kindervater FKV_2007_2008_Applications Applications-1: 12
High performance single engine aircraft flying at high altitudes
Grob/E-Systems D 500
• wing span: 33 m (40,5 m²),
GFRP/CFRP laminates/sandwich
• fuselage: 12 m
• MTOW: 4200 kg
• Vcr : 300 km/h
D 500 fuselage manufacturing
• mould in two part divided along the
x-axis
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Kindervater FKV_2007_2008_Applications Applications-1: 13
Aeronautical composite applications cont´d
Military aircraft
• major use of carbon f ibre UD-prepregs in autoclave technique
with stepwise vacuum consolidation
• thermoplastic matrices ( PEEK, PEI, PES) and manufacturing
technologies under consideration• 80% of outer composite surfaces, 45% of total weight
• tool ing and moulds in CFRP sandwich and monolithic designs
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Kindervater FKV_2007_2008_Applications Applications-1: 14
Alpha Jet - Horizontal stabiliser
• Development/manufacturing:
Fa. Dornier/DLR Stuttgart (1980)
• CFRP-Prepreg, autoclave in-situmanufacturing of skins and ribs
• cost reduction: 7,5 %
• mass reduction: 14%
• mass: metal: 62 kg, CFRP: 53kg
• single parts: metal: 215, CFRP:80
• fasteners: metal: 5000, CFRP: 1200
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Kindervater FKV_2007_2008_Applications Applications-1: 15
CFRP-mould and C-scan inspection for Eurofighter fuselage shell
CFRP-Mould
• provides thermal compatibility of
CFRP shell and mould
C-scan of CFRP fuselage uppershell
• detects voids and delaminations
which could have occurred during
autoclave manufacturing
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Kindervater FKV_2007_2008_Applications Applications-1: 16
Aeronautical composite applications cont´d
Civil transport aircraft
• dual use from military applications
• autoclave technique is the standard manufacturing technology
using GFRP
and CFRP tapes and fabric (lower cost) prepregs
• automation by tape-laying, mechanical f inishing and ultrasonic
scanning• Use of textile pre-forms and resin infusion techniques will
increase
• primary structures: horizontal and vertical stabil iser in stringer
stif fened monolithic shells/panels and frames
• composite wing and fuselage under development• secondary structure: f laps, spoiler, fairings, engine cowlings,
radar domes, interior panels in Nomex core sandwich with f ire
resistant resins
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Kindervater FKV_2007_2008_Applications Applications-1: 17
History of CFRP Applications at Airbus
Quelle: Airbus/Breuer
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Kindervater FKV_2007_2008_Applications Applications-1: 18
A300/310 vertical CFRP-stabilizer
• production since 1985
• total height: 12 m
• two stringer stiffened
shells are assembled via
spars
Mass: Al: 640 kg, CFRP: 508kg (-20%)
single elements: Al; 2072, CFRP: 96
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Kindervater FKV_2007_2008_Applications Applications-1: 19
A300/310 vertical CFRP stabiliser - design and manufacturing principle
Half shell of vertical stabiliser
Manufacturing steps: - tape lay up of outer shell - tape winding
around rib moulds - autoclave curing - de-moulding
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Kindervater FKV_2007_2008_Applications Applications-1: 20
American Airlines Flight 587, Belle Harbour, NY, 12th Nov. 2001
Vertical stabil izer (tail fi n) attachment point
One of the forward attachment points
Right side forward and center attachment points
Left forward attachment point
One center and two aft attachment points
Forward attachment points of fin (attached to empenage)
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Kindervater FKV_2007_2008_Applications Applications-1: 21
Airbus CFRP applications
AFRP or GFRP
CFRP
Source: EADS Airbus
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Kindervater FKV_2007_2008_Applications Applications-1: 22
Composite material distribution
Source: EADS Airbus
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Kindervater FKV_2007_2008_Applications Applications-1: 23
Share of structural materials
Source: EADS Airbus
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Kindervater FKV_2007_2008_Applications Applications-1: 24
Weight saving through composite application
Source: EADS Airbus
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Kindervater FKV_2007_2008_Applications Applications-1: 25
Horizontal
Tail Plane
Floor Beams
for Upper Deck
Rear Pressure
Bulkhead
Outer Flaps
Vertical
Tail Plane
J-Nose
Center Wing Box
Section 19
GLARE®
Section 19.1
Belly Fairing
Wing Ribs
New Components for A380
Source: Airbus Deutschland GmbH
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Kindervater FKV_2007_2008_Applications Applications-1: 26
Boeing 787 Dreamliner
• CFK-Tragflügel
• CFK-Rumpf
• CFK-Anteil Struktur: ca. 50%
CFK-Rumpfsektion (Barrel)
CFK-Cockpitbereich
Rohbau
Fertiges Bauteil
Quelle: Boeing.com
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Kindervater FKV_2007_2008_Applications Applications-1: 27
Gondelkonzept – ein CFK-Rumpf in neuer Bauweise
-Gesamtkonzeption-
CFK-Rumpf in neuer Bauweise:
• separat
ausgeführter
druckbelüfteter
Passagierraum (1) mit Unterschale(2), mittragenden Fußbodenplatten(3) und mittragenden Sitzschienen (4)
• (nicht) mittragender und (nicht)
druckbelüfteter Frachtraum (5)
als
ausgeprägte Opferstruktur hinsichtlich Crash/Impact inkl. „plastische“ Gelenke (6), Crashrohre(7), Zugbänder (8) und Impactschutz-
Außenschale
(9)
1
24 3
5
76
8
9
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Kindervater FKV_2007_2008_Applications Applications-1: 28
Gondelkonzept – ein CFK-Rumpf in neuer Bauweise
- Demonstrator: Schalenkonzepte in Nasstechnolgie -
Passagierraum - integral
gefertigtes
Sandwich in
SLI-Verfahren
• Aufbau: Detektorschicht (1), Schaum (2), außenliegende Stringer (3), tragende
Innenhaut
(4),
innenliegende
Spanten
(5)
• Verbindungstechnik - Bolzenverbindung
durch
ununterbrochene Verbindungslaschen (6) aus Hybrid-
Composite CFK/Titan
Frachtraum - integral gefertigtes Sandwich
mit Hybridkern im VARI-Verfahren
• Aufbau:
innen
NOMEX-Wabe
(7),
außen
PEI-Schaum (8) mit PBO-Fangschicht im
Decklaminat (9), Innenhaut (10)
1
23
4
5
6
6
78
910
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Kindervater FKV_2007_2008_Applications Applications-1: 29
CFK-Rumpf Demonstrator (ILA 2002/Berlin)
HGF - Project „ Schwarzer Rumpf“
Gondel
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Kindervater FKV_2007_2008_Applications Applications-1: 30
Project „ Schwarzer Rumpf“ – Gondola concept
Rumpfkontur: Dr. Kolesnikov (DLR; SM-BS)
Energy absorber
Tension strap Plastic
hinges
Impact&fire resistant shell
crash
bulkheads
Protective
shell:
Impact&fire
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Kindervater FKV_2007_2008_Applications Applications-1: 31
Crashtest und numerische Simulation
Untersuchung eines Crashspants („Schwarzer Rumpf“)
Film des Crashtests im BK-Fallprüfstand
• Fallmasse: 200 kg
• Aufprallgeschwindigkeit: 8 m/s
Vergleich Test und Simulation
• Ca. 7500 Finite Elemente
• Randbedingungen entspr. Testumgebung• Spezielle Interfaces für Spantablösung
HGF - Projekt „ Schwarzer Rumpf“
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Kindervater FKV_2007_2008_Applications Applications-1: 32
A310 and A320 water tanks
A320 waste water tank
• filament winding with carbon or aramid
fibres
A310 fresh water tank in
differential design
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Kindervater FKV_2007_2008_Applications Applications-1: 33
Do328 composite application in the rear fuselage and empennage
structure
Source: Flemming, Ziegmann, Roth
Total: -30% Gewicht
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Kindervater FKV_2007_2008_Applications Applications-1: 34
CFK im Triebwerk: Fan-Schaufel; Verstellring
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Kindervater FKV_2007_2008_Applications Applications-1: 35
Aeronautical composite applications cont´d
Helicopters
• Wide use of composites in airframes, innovative adaptive rotor
systems and rotor blades, crash energy absorption management
• use of GFRP, CFRP and aramid fibres (UD- tapes and fabrics)• Monolithic frames and sandwich shells and panels
• manufacturing in autoclave technique, hand-lay-up, RTM, resin
infusion
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Kindervater FKV_2007_2008_Applications Applications-1: 36
Helicopter composite applications
BK117 composite airframe
• CFRP and CFRP/aramid nomex
sandwich in autoclave technique
• monolithic CFRP frames
EC135 main rotor system
• design without mechanical
hinges
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Kindervater FKV_2007_2008_Applications Applications-1: 37
NH90 and Tiger composite applications
NH90 composite
applications
• airframe in CFRP and
AFK Nomex, AFK/CFRPhybrid laminates
• rotor systems in CFRP
and GFRP
Tiger antitank helicopter
• airframe in CFRP and
AFK Nomex
• rotor systems with
CFRP and GFRP
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Kindervater FKV_2007_2008_Applications Applications-1: 38
Helicopter crashworthiness CW- system design aspects -
CW landing
gear
CW Airframe
CW
Crew/Troop
Seats
CW Fuel system
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Kindervater FKV_2007_2008_Applications Applications-1: 39
NH90 airframe crash components
Objectives:• development and validation of EA
structural concepts• component crash tests
• validation of simulation methods
• generation of input data for KRASH
Sub-structures and components:• floor beams - sandwich concepts
• structural intersections
• sub-floor-box with fuel tank
• complete frame 6
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Kindervater FKV_2007_2008_Applications Applications-1: 40
Tiger Cockpit sub-floor sine wave beam
EA sine wave beam
carbon/aramid hybrid
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Kindervater FKV_2007_2008_Applications Applications-1: 41
Tensor skin concept
Tensor skin
design
Corrugated core: Dyneema fabric
Picture frame shear test Panel impact test
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Kindervater FKV_2007_2008_Applications Applications-1: 42
Design Concept for Composite Demonstrator (1)
Final Design of Composite Demonstrator
Carbon/ AramidCrush cones
Sandwich skinTriggered lower rib
CFRP beam
Aluminiumangle
Trolleyattachments
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Kindervater FKV_2007_2008_Applications Applications-1: 43
Design Concept for Composite Demonstrator (2)
Sandwich Skin Concept
Aramid
Rohacell coreCarbon
Design of sandwich skin edge
Evaluation in static test (IAI) Dynamic evaluation at 1 m/s (DLR)
AVI
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Kindervater FKV_2007_2008_Applications Applications-1: 44
Crushing Sequences (60ms) with z-Velocity
Final Simulation of Water Impact• Non-linear material properties for aluminium• Composite damage law: degenerated bi-phase model• SPH water model: Same as for full-scale helicopter simulation (MAT 7)• Separation of sandwich layer
AVI
Bi d I t
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Kindervater FKV_2007_2008_Applications Applications-1: 45
• Composite leading edge with energy absorbing tensor skin core
• Dyneema/epoxy (HPPE) tensor skin unfolds to absorb impact energy
• Simulation tools under development to support design and certification
• Figure shows FE simulation of quasi-static indentation testDetail of tensor skin geometry
Composite LE after quasi-static test (NLR)
Bird ImpactComposite sandwich shell with tensor core
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Kindervater FKV_2007_2008_Applications Applications-1: 46
NH90 Nose Landing Gear Crashtube
Partner: Liebherr Aerospace
Limit load: 110 kN; stroke: 190 mm
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Kindervater FKV_2007_2008_Applications Applications-1: 47
Composite Airframe Crash Structures(EU project CRASURV/FW4)
Impact velocity:
7 m/s
Commuter structure
mass: 719 kg, E0: 19 kJ
Airliner structure
mass: 433 kg, E0: 10,6 kJ
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Kindervater FKV_2007_2008_Applications Applications-1: 48
Composite Propellers
• application of glass and carbon hybrids
with high performance epoxy matrix
• share of glass and carbon in hybrids
controls the torsion frequency of the
propeller blade
• less weight and high design flexibility
• high fatigue performance regarding the
high vibration loading
• environmental resistance (sand, oil, salt
water)
• good impact resistance (hybrids!) anddamage tolerance
• low repair costPropeller for regional aircraft SAAB 2000
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Kindervater FKV_2007_2008_Applications Applications-1: 49
Composite space applications
• structures, antennas, and mirrors with low or zero thermal
expansion under changing sun radiation condit ions
• very stiff and extreme light structures (ultra high modulus
(UHM) graphite fibres)
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Kindervater FKV_2007_2008_Applications Applications-1: 50
CFRP antenna structure for space appl ications
• CFRP tubes with rovings, fabrics or
braidings and epoxy matrix
• filament winding, fabric winding on
mandrel, pultrusion
• major advantages:
- less weight
- very stiff with UHM graphite fibres
- high Eigenfrequency provides good
positioning accuracy
- no thermal strains or deformations
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Kindervater FKV_2007_2008_Applications Applications-1: 51
CFRP Satellite Central Tubes and Adapters
Launch Vehicle Adapter
Spacebus Central Tube (Saab)Spacebus 4000:
• Automated fibre
placement