‘zwaarwegende’ voordelen van lichtgewicht ontwerpen adriaan beuker… · aerospace & wind...
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‘zwaarwegende’ voordelen van
Lichtgewicht Ontwerpen
De Fabrique, Constructeursdag: ‘Out of the box’ ontwerpen
Maarssen, 19 november 2013
Adriaan Beukers
het domein voor composiet constructies
verder terug
motivation and introduction:
Durable Lightness dematerialization
vs. miniaturization
lichtgewicht constructies
tall structures and transport systems struggle with gravity
transport: ‘everything what moves or is being moved’
liquid fuel history: ‘a one century history of slash and burn’
SABIC/GEP-DSM
BASF/DSM
Emirates
Delta Airlines
10-20 -->100$/barrel
Cheap Materials become Scarce e.g. cheap oil, easy exploitable wells, new economies, EC2020
Transport and velocity domains
Total (system + payload) weight, so reduce system weight!
Specific drag 2 drag per unit system weight
15kgf PREQ to move
100kg WTOTAL
extreme efficiency
ratios
less system weight, more payload
Reduce (empty)
System Weight
EFFICIENCY improvements since the 50’s, aerodynamics: L/D ≈ 15%
propulsion: SFC ≈ 40 %
structure : 0.50 > OEW/MTOW > 0.60
Major R&D Challenges:
Structures, Materials &
Manufacturing Techniques
A320/B737 - alikes
structure efficiency
used for aircraft
OEW / MTOW =
42 ton / 74 ton = 0.56
Johnston distribution OEW:
50%: 21ton for systems, crew and power-plant(s)
50%: 21ton for structure in total
• 10.5ton for wing , undercarriage (6% ) and movables (6%), (12%=5 ton)
• 10.5ton for fuselage and empennage (13%)
• 16.0ton for wing, fuselage and empennage shell structures (38%)
FOCWA-ColdFeather 1995, 3 ton weight reduction per trailer!!!!
max weight saving with composites for aluminium shell structures
is about 25%, equal to 4ton, for a A320 or B737 alike!
Energy saving: 667 GJ/year.100kg Specific energy content: 35 MJ/litre
So fuel saving per year per 100kg: 19000 litre
Sell tickets priced per kilogram not per seat!
A320/B737 AIRCRAFT mass reduction pays
Minimize Airmiles (point to point)
Amsterdam - Dubai - Bejing: KLM direct flight: -30% airmiles, 2 x ticket price
Emirates policy: ‘sell A380-seats instead of oil’
Aircraft profit breakeven at ≈85%,
KLM profit ≈5$/passenger÷0.05$/kg, Easy Jet profit 1.2$/passenger
Life-time energy savings per 100kg average values for energy
savings by
weight reduction
IFEU 2004, 1GJ is about 30lt kerosine
42,000lt
450,000lt
600,000lt
Life time ENERGY SAVINGS HIGH SPEED FERRIES
33% reduction by weight
- 47 ton/100kg.lifetime (-7%)
E-glass reinforced composite
-7% kerosine
1650GJ//35MJ/lt
steel
aluminium
gfrp
+
added
values
Design and Production of Composite Structures
dematerialisation & miniaturization
optimization
Design and Development Strategy
textiles
plastics composites
integration vs. segregation
novel fibre-polymer composites
downstream manufacturing
reduction of costs & energy
reduction of emissions & waste
multidisciplinary R&D
FIBRE AND WIRE PROPERTIES for lightweight engineering, aerospace and sport equipment
FROM ABSOLUTE (E, σ) TO SPECIFIC PROPERTIES (Ex/ρ, σy/ρ)
FIBRES & RESINS: VOLUME, ARCHITECTURE AND HANDLING
roadmap
material
morphologies
& processes
LOW PRESSURE, LOW COST void free infusion free of autoclaves micro bubles carry entrapped voids
classical markets
aerospace & wind
energy show
highest global
growth now,
be in front
of the big
volume
emerging
composite
markets!
CAGR: compound anual growth rate
size of bubbles: indicating for market size ref. Lucintel
Composites Global Market Opportunity 2012-2017
Concept, materials and manufacturing technique selection
Life cycle cost driven
Composiet in Opmars 1 civil constructions 2013
Concept, materials and manufacturing techniques selection
Fast competition structures, maximum performance driven
Composiet in Opmars 2 America’s Cup 2013
Concept, materials and manufacturing techniques
Performance/price driven
Composiet in Opmars 3
2013 BMWi3
Concept, materials
and manufacturing technique selection
Price/performance driven
Composiet in Opmars 4
Airbus 350, 2013
Taniq
Actiflow
Infinious
ALE
Airborne
K&vE
WMC/CompEx
Bond Laminates
Conform/Hylid
DTC / Mupio
Feltrin Composites
CLC / LS
Euro Enaer (‡)
Senz/Protension
MOCS/CTC
proof of the
structure is
in the testing
Structure efficiency
slender beams and plates
dominated by bending
or compression buckling
material specific efficiencies determine:
fig.4.3.3: Compression panel efficiency
for different types of stringers
fig.4.3.1: Z-section stringer, pitch b, length L, As cross sectional area
fig.4.3.2: Minimize equivalent thickness t ≥ p / versus yield strength, plate buckling L, t, and b and local and global stringer buckling (L and r = I / As)
4.3 STIFFENED SKIN STRUCTURE EFFICIENCY
1932- Buckling or compression critical wing panels
Source: A. Rothwell
cfrp gfrp alu
Structure Design Efficiency (factored for environment)
global material efficiency, load intensity
structures free of discontinuities
final structure efficiency, integrity and durability depend
on ‘smart’ design of joints, cut outs and load trajectories
Good material, Poor structure the inconvenient true of a C141 Starlifter
compression
efficiency
comparison,
stiffened panel
configuration, ref. Prof. Rothwell
machined monolithic wing panels:
poor splices, poor radii, poor drain holes for a fatigue and
(fungus, fuel tank) corrosion sensitive environment
FLOPPY AND FROZEN TEXTILES
Ultimate Lightness textile
structures
in aerospace
George Cayley ’s
paradigm ca.1799
Frozen textile = composite structure
Segregate functions to solve ‘design’problems
27 CompEx for BOSAL & SKODA | 27
Design, prototype & test a lightweight,
durable exhaust system
• Mass reduction at least 20% (60%)
• Cost penalty per saved kg : < € 10 (same for hybrid cars)
• Dynamic & acoustic properties: comparable
Composite redesign, example 1
CompEx Concept
Ferrari California exhaust system
Pyrogel
Mesh
Carbon skin
Superwool
28 | 29
CompEx technology
How it works
Insulation layer1
Insulation layer 2
Mesh
Carbon skin
Carbon Composite skin 200˚C resistant
Exhaust exterior <200˚C
Exhaust gases up to 950˚C
Mesh
Insulation layer 1 1100˚C
resistant
Insulation layer 2 650˚C
resistant
29 | 29
Concept
Adapter
• Inner tube conveys exhaust gases into composite exhaust
• Outer tube is connected to the composite exhaust outer shells
30 | 29
1. CompEx Heat Tests Heat testing is done on prototype 1
• Thermocouples on 10 different locations
• Temperature measures as function of time at 6000 rpm/ 690 Nm torque
• No adhesive, only clamping rings
31 | 29
1. CompEx Heat Tests
32 | 29
2. CompEx Acoustic Testing Testing of prototype 3 vs. steel pipe
Speaker Inlet microphone Outlet microphone
33 CompEx for BOSAL & SKODA | 27
2. CompEx Acoustic Testing
CompEx Technology A light weight, durable and high performance exhaust system concept Sotiris Koussios & Adriaan Beukers
Faculty of Aerospace Engineering Delft University of Technology
packaging on the move, from technology push to market pull 1
Impertinate design: new materials and processes,traditional morphology
oak barrel mimics, Eugene Kelly ‘37 mimics, B787 metal mimicked
composite AC; from refillable to disposable lightweight packaging
LIGHTER TRANSPORT COUNTS Adriaan Beukers, TUDelft
packaging on the move, from technology push to market pull 2
Exchangeable bag-in-box light weight packaging, low cost,
collapsable:‘flexy-fust’: beer, wine, chemicals
30lt: from 11 to 3.75kg, no CO2 for beer
LIGHTER TRANSPORT COUNTS
packaging on the move, from technology push to market pull 3
from refillable to disposable lightweight packaging:
via ‘flexy-fust’ to ‘key-keg for beer, wine, chemicals, et cetera
30lt: from 11 to 1.5kg’, no CO2 for beer, better taste
LIGHTER TRANSPORT COUNTS
Jan
Veenendaal
Bert
Hanssen
THE END
-KEYKEG DISPOSABLES (pet) - -2010: ca 300.000 units 30lt (-10kg)
no 10kgCO2 bottle per 50 beer kegs
no NaOH cleaning & final water flushing
(chemical disposal)
reduced transport mass ca 3000ton
saves transport equivalent to 150 trailers
huge improvement of used raw material
(from 7/1 to 3/1) and energy balance!?
packaging on the move, from technology push to market pull 4
LIGHTER TRANSPORT COUNTS
‘zwaarwegende’ voordelen van
Lichtgewicht Ontwerpen
De Fabrique, Constructeursdag: ‘Out of the box’ ontwerpen
Maarssen, 19 november 2013
THE END
het domein voorcomposiet constructies
From Liquid To Gaseous Energy Carriers 2013
Shale gas, deep well an-organic chemistry from global to local resources
equal to liquid fuel history: ‘a new century of slash and burn’
Shell 2013: US, China, Brazil,
‘very disappointing return
on investments’
CEO Peter Vosscher
Periodic System of Elements
Composites, engineering polymers and fibers versus metals
Ice, mud and concrete are implicit light materials too
polymer
composites
light
metals
heavy metals
minimum mass and energy
a strategy for design
the building blocks for materials
INDUSTRIAL MANUFACTURING, THE FASTER THE BETTER reduce mass of rotating mandrels reduce mass of head place dry fibres keep them straight, simple artificial geodetics
Life-time energy savings per 100kg
average values for energy
savings by weight reduction
IFEU 2004
1GJ is about 30lt kerosine
Energy carriers, energy transformers
Energy carrier
Transformer
Transport system
Structure materials
Carrier follows transformer
PERI OD ENERGY CARRIER/TRANSFORM ER
TRANSPORT SYSTEM MATERI ALS
up to 1830
direct: wood, wind, water,
animals, man
walking, horses, barges, coaches
wood, linen, copper, brass and iron
1830-1900 Coal steam engines coaches, ships, trains wood, linen,
iron, steel
1900-1940 Coal electric dynamo trains, cars, buses wood, linen, plywood,
iron, steel
1903-2003 Oi l internal combustion
engines,
piston and
turbine engines
cars, buses, flying machines,
all aluminium aircraft with
pressurised fuselages
wood, plywood, linen,
iron, steel, aluminium,
polymers
1960-2025? Oi l high efficient by-pass
turbine engines supersonic aircraft (2001†)
classical subsonic aircraft iron, steel, aluminium,
polymers, titanium,
composites
1970-1990 Nuclear centralised electricity
distribution
high velocity trains, steel, aluminium,
composites
1990-2025? G a s clean and efficient
energy supply,
CH4 and H2
city transport steel, aluminium, titanium, advanced composites, advanced alloys, ceramics
2025 – future? Hydrogen?
Nuclear?
Wind/Solar?
Oil
fuel cell?
gas?
bio-fuels?
direct electricity
direct elektrocutie
highest caloric value
per unit volume and
mass
sustainable transport: smart cars, busses, new train concepts, high velocity trains composite aircraft/BWB
new polymers, ceramics, fibres, new reinforcing materials and improved metals.
transport and storage
Gaseous energy carriers
lightweight gascontainer, from liquid
to gaseous energy carriers
lpg, cng, H2, metaan
ref. S. Koussios & L. Zu
Design and Development Strategy
Design and Production of Composite Structures cooled trailer system weight
reduced from ca. 9300
to 6500 kgf
1995, Focwa/Cintec 30% weight reduction challenge
Design and Production of Composite Structures
The end
‘COMPOSITES’
STADE composite waste management: reduction potential of 40%
waste equals per year: 14600kg/€19.4 million = 1328€/kg
(53/47% un/planned)
DISSEMINATION
UTILIZATION
DEVELOPMENT
KNOWLEDGE
• Airbus • Stade • Nantes • Illescas
carbon fibre
pre-preg waste and rejection
cost
Assembly Single Parts, AutoCLave, Ties(links)
∑ €19,4million
Structures
Processes
Materials
composites
Thermal properties
of polymers
glass transition
melt
process
amorphous
semi-crystalline
textile
structures
in aerospace
Textile Morphologies
the flatter the better
down stream manufacturing
fig. 2.1:
Typical commercial aircraft weight distribution
Source: R.W Johnson NASA
fig. 2.2:
Part count distribution
43 % Shell: skin, stiffeners, frames
16 % keel: wheel wells etc.
12 % floor assemblies
11 % door assemblies
10 % bulkheads
8 % windows
Aircraft Structures in Fractions
1985
Fractions of weight, parts and cost
Metal mimics:
Function integration?
Industrial manufacturing?
Composite Fuselages
Design and Production of Composite Structures
6 seat aircraft
pressurized cabin empty weight 1300 kg
cruise speed 400 km/h
range 1100 km
1997, Extra 400/500: conceptual, aerodynamic and
structural design (integration of parts, mechanics and physics)
Lighter transport counts
design of pressure cabins:
frame
pitches
Combine Physics & Mechanics
Frame pitches
A look beneath the surface