smart production technology for complex carbon …...smart production technology for complex carbon...
Post on 21-May-2020
9 Views
Preview:
TRANSCRIPT
Smart production technology
for complex carbon composites
Cevotec | APAC Innovation Summit AM & PE
Thorsten Groene | Managing Director & Co-Founder
November 22, 2016
November 2016 2milestones in composites
milestones in composites
Carbon composites – from
(aero) space to our daily lives!
Market EUR 12.3 billion | Growth2020 +11% p.a.
November 2016 3milestones in composites
milestones in composites
Yet development and production are problematic
Complex composites are still manufactured by hand
Development and production require specialists
Production cycles take too long
November 2016 4milestones in composites
milestones in composites
composites.
revolution.
technology.milestones in composites
New technology for automated production of complex composites
User-friendly software for rapid product development
November 2016 5milestones in composites
milestones in composites
The Cevotec solution: Breaking down complexity!
November 2016 6milestones in composites
milestones in composites
Fiber Patch Placement additive manufacturing for composites
·Truly additive manufacturing
· Industry 4.0
·Perfect symphony of software & hardware
·15 man-years of development work (w/ Airbus, TU Munich, et al.)
Innovation Benefits
Online Demo Video :
http://bit.ly/1W0B7jL
150% higher strength & stiffness
25% less material & weight
Unique design and aesthetics
November 2016 7milestones in composites
milestones in composites
Fiber Patch PlacementMain applications
Complex geometry productsComplex fiber reinforcements
for ANY composite product
end-to-end automation | high quality | high volumes reduce weight & cost | increase mechanical properties
November 2016 8milestones in composites
milestones in composites
Without
Cevotec
Rapid development + efficient production + better products
With
Cevotec
Rapid product development
· Easy change of layouts
· Results can be simulated
Quick iterations
Efficient production
· 0% scrap
· 80% time reduction
Tailored reinforcement
Better boards
· Better mechanical properties
· Great optics
Higher margins
Use Case: complex reinforcements
Example: kiteboard
Design Phase Production Final Product
November 2016 9milestones in composites
milestones in composites
The Cevotec business modelOne-stop-shop for patch-based production technology
Manufacturing Hardware
Today
Technology as a service
2017 launch:
Production equipment & software
Software
Development & production of customer-specific parts
Market entry, awareness & technology adoption
Equipment sales, software licenses, consumables
Long-term business model
Development
2015 2016 2017 2018 2019 2020 2021 2022
100%
50%
Focus of business activity (illustrative)
Technology services Equipment and software
Felix Michl (Dipl.-Ing.)
Technology
Co-developed the FPP technology
Aerospace engineer
8 years composite experience
Dr. Neven Majic (Dr.-Ing.)
Software and
Digital Product Development
Ph.D. in structural simulation
8 years composite experience
Thorsten Gröne (MBA)
Business
MBA from IESE and UC Berkeley
8 years strategy consulting
Expert project management skills
Mentor & advisor
Prof. Klaus Drechsler
Professional & academic experiences of the team
milestones in composites
November 2016 11milestones in composites
SAMBA - industrial Fiber Patch Placement production systemAvailable in March 2017
in cooperation with
Launch at
JEC World 2017
March 14-16
Paris
MARKET LAUNCH
Paris
March 14-16, 2017
milestones in composites
November 2016 12milestones in composites
ARTIST STUDIO - engineering software for Fiber Patch PlacementAvailable in March 2017
Generation of high performance FPP laminates Generation of production data
Outlook: Additional modules with FE-based functionalities to be added in future versions of Artist Studio
MARKET LAUNCH
Paris
March 14-16, 2017
Standalone CAD-CAM Software with two modules
Module Patch Artist Module Motion Artist
Artist Studio
milestones in composites
November 2016 13milestones in composites
Composite production line with Fiber Patch PlacementIntegeration of patch technology into industrial composite lines
milestones in composites
November 2016 14milestones in composites
Composite production line of the future – prototype in NLAirborne and Siemens built digital factory in the Netherlands (Dec 2015)
Source: Airbone (http://www.airborne.com/airborne-and-siemens-build-digital-factory/)
November 2016 15milestones in composites
milestones in composites
November 2016 16milestones in composites
milestones in composites
Fiber Patch Placement prototype systemhttps://www.youtube.com/watch?v=35V5exLR9IA
The concept behind the story
Why Patch Placement works so well, scientific results, and details of implementation
milestones in composites
November 2016 18milestones in composites
Bionic lightweight designMotivation for Fiber Patch Placement
Leaf
Natural Fibrous Structures
Human bone
Tree trunk
Technical Structures
Hall construction
airport Stuttgart
Topology
optimized chassis
Curvilinear carbon
fiber orientation
Fibers follow curved paths
Transferring the principle for lightweight construction
New curvilinear textile technologies
Fiber Patch Placement
Direct patch placement on
3D geometry or along 3D load paths
November 2016 19milestones in composites
milestones in composites
Massive drop in strength in classical laminatesMost problematic aspect of multiaxial non-crimp fabrics
Fact
Multiaxial non-crimp fabrics such
as quasi-isotropic lay-ups cannot
exploit the full potential of the
material.
Example
45° deviation to a tension-based
load path leads to a extremely
reduced strength (>90%)
No optimal lightweight design
0° Ԧ𝐹
α
Unidirectional properties of patch laminates
FPP UD strength: 65% – 80% | FPP UD stiffness: 85% – 90% | compared to UD endless fiber
milestones in composites
November 2016 20milestones in composites
Strength increase of FPP due to curvilinear fiber orientationDemonstration at an open hole specimen
Source: O. Meyer, Short fibre preform technology for load path aligned manufacturing of fibre reinforced plastic components, Doctoral thesis, University of Stuttgart, 2008
Biaxial non-crimp fabrics Load path oriented fibers (FPP basis)
Mass-specific
maximum strengthF
F
F
F
+120%
milestones in composites
November 2016 21milestones in composites
Stiffness increase through load optimized fiber laminateMeasured test results
Source: Cevotec and Technische Universtität München
5,23
13,3
5,31
12,35
5,05
13,6
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
quasi isotropic lay-up FPP lay-up
Mass specific stiffness [kN/(mm∙g)]
+150%
simulation specimen 1 specimen 2 simulation specimen 1 specimen 2
150 mm
210
mm
F F
F F
milestones in composites
November 2016 22milestones in composites
Patch reinforcements improve conventional lay-upsLoad-path oriented reinforcements reduce material, weight and cost
MT
MT
Quasi-isotropic lay-up Lay-up with FPP patch layers
4 unidirectional layers
with 2 FPP patch-layers8 unidirectional layers
45°-45°90°
0°0°
90°-45°45°
MT
MT
FPP45°
-45°-45°45°FPP
8 unidirectional layers
20% weight reduction
4 unidirectional layers + 2 FPP Lagen
November 2016 23milestones in composites
milestones in composites
Laminat design softwareOptimal splice distribution key to performance
Unoptimized patch laminate Optimized patch laminate
November 2016 24milestones in composites
milestones in composites
The virtual FPP process chainFrom design to preform in an integrated process
CAD design
· Spacially curved
surfaces
· Concave & convex
· Undercuts possible
Laminate design
· Curvilinear fiber
orientation
· Patch laminate
optimization algorithm
· Optimal distribution of
splices
Process simulation
· Simulation of robot
movements
· Feasability check
· Offline machine
programming
Automated preforming
· Fully automated process
from tape to preform
· Automated preform
handling and removal
milestones in composites
November 2016 25milestones in composites
How to deal withcomplexity
in composite production?
In composite production,complexity
is the enemy of automation
complex3D geometry
complexcurvilinear fiber architecture
November 2016 26milestones in composites
milestones in composites
R=50 mm
90° @ R=1 mm
R=60 mm
„+ & -“ curvature
November 2016 27milestones in composites
milestones in composites
The Cevotec solutionFiber Patch Placement (FPP) – additive manufacturing for composites
1 2 3 4 5
Various patch options
1.Feed dry, bindered CF spread tow and inspect quality
2.Cut spread tow into fiber patches
3.Inspect fiber patch quality
4.Pick up patch, check patch position
5.Position patch on 3D preforming tool
Five steps.Endless advantages.
November 2016 28milestones in composites
milestones in composites
Fiber Patch PlacementFive steps. Endless advantages. Truly additive manufacturing for composites.
1 2 3 4 5
1.Feed dry, bindered CF spread tow
and inspect quality
November 2016 29milestones in composites
milestones in composites
Fiber Patch PlacementFive steps. Endless advantages. Truly additive manufacturing for composites.
2.Cut spread tow into fiber patches
3.Inspect fiber patch quality
1 2 3 4 5
November 2016 30milestones in composites
milestones in composites
Fiber Patch PlacementFive steps. Endless advantages. Truly additive manufacturing for composites.
4.Pick up patch, check patch position
1 2 3 4 5
November 2016 31milestones in composites
milestones in composites
Fiber Patch PlacementFive steps. Endless advantages. Truly additive manufacturing for composites.
5.Position patch on 3D preforming tool
1 2 3 4 5
Looking for: Manufacturing innovators to bring their products
to the next level with patch placement technology!
Offering: Evaluation, feasibility studies, prototyping services
production systems, software & support
www.cevotec.com | thorsten.groene@cevotec.com | +491752964108
Supported by:
Smart production technology
for
complex carbon composites
· Innovation in composite production: Fiber Patch Placement
· Broad range of applications across industries
· Production systems, design software, services Cevotec
milestones in composites
Annex
November 2016 34milestones in composites
milestones in composites
Medical orthosisSample application
Medical orthosis
Advanced geometry
Undercuts
Small radii
Net-shape preforming
Local thickening at critical areas
Tailored stiffness by fiber design
10 cooperating robot axis for
direct 3D preforming
November 2016 35milestones in composites
milestones in composites
Bicycle saddleSample application
FPP bicycle saddle
Extreme low weight (<70 g)
Unique and attractive optic
Net shape preforming
Local thickening at critical areas
Stiffness tailored to customer
requirements
milestones in composites
November 2016 36milestones in composites
Local reinforcement for holes / jointsSample application
Image source: Airbus Group
Shear stress reinforcement
Extreme low weight (1-3 g)
Unique and attractive optic
No material scrap during manufacturing
Very good load distribution in component
Higher increase of bearing strengths
compared to conventional reinforcements
Geometry tailored to customer
requirements
Dry fiber reinforcement patch
Application of reinforcement patch at bolt joint
milestones in composites
November 2016 37milestones in composites
Unique design and aestheticsSample application
FPP bicycle saddle
Radially arranged, 60mm long
patches with round cutting edge
Scale-like pattern
Tri-directional patch orientation
Variable patch length with straight
cutting edge
www.cevotec.com | thorsten.groene@cevotec.com | +491752964108
Cevotec is supported by:
Smart production technology
for
complex carbon composites
· Innovation in composite production: Fiber Patch Placement
· Broad range of applications in large and growing composites market
· Production systems, design software, services Cevotec
milestones in composites
top related