automation - easyfairs€¦ · cytec industrial materials . ... localised slashes - slash only...
TRANSCRIPT
A primary objective of the project is to high volume manufacturing
affordability of composite structures through;
a) Optimised cutting solution and slash implementation
b) Improve accuracy of component with cure distortion studies and tool optimisation
c) Automated angle / cross plying of multi layer formats
Project Overview of ACTIVATE- Affordable composites for high volume manufacturing of automotive structures
2 methods of cutting have been investigated;
1. Non-contact cutting using laser technology -University of Nottingham
2. Contact Cutting using Assyst Bullmer facility and equipment
ACTIVATE
(a) OPTIMISED CUTTING AND SLASH IMPLEMENTATION
Nottingham University successfully conducted trials of cutting dry fabric,
prepreg and composites using laser technology. However challenges remain of
optimising to use it to implement slashes
ACTIVATE
(a) OPTIMISED CUTTING AND SLASH IMPLEMENTATION
Trials with the support of Assyst Bullmer plant showed successful slash implementation via ‘contact cutting’
ACTIVATE
(a) OPTIMISED CUTTING AND SLASH IMPLEMENTATION
ACTIVATE
Limitations of current slash implementation
• Only a fixed slash pattern is achievable
• Cost due to high wear rate of roller die cutting knives. The wear rates
are significantly higher for certain slash angles e.g. 60˚
• Maximum die width 650mm hence, material width limitation
How do we overcome the above through ACTIVATE:
Localised slashes - Slash only where you need to!!
Low process cost, can be implemented by any cutting machine and no width
limitation.
(a) OPTIMISED CUTTING AND SLASH IMPLEMENTATION
ACTIVATE
Punch
Die
Blank holder
University of Nottingham are working on generic component – Dust pan to generate a localised slash pattern
8 UD plies 0/45/90/-45/-45/90/45/0
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Localised slash pattern generation
Step 1: Insert cutouts where surface curvatures are high
Step 3: Determine minimum bounding area
Step 2: Surface flattening
Step 4: Generate slashes in the cut-off region in Step 2/
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Comparison of drapability of continuous, D-form and localised slashes material
Non-slashed
Localised slashes
D-form
Localised slashes on net shape
ACTIVATE Shear Angle– Model comparison
Stress concentrations of UD ply for double-dome geometry for (left) conventional UD ply (no slashes), (centre) a continuous slashed part (Dform) and (right) a localised slashed part.
Comparison in net shape
ACTIVATE
(b) IMPROVE ACCURACY VIA CURE DISTORTION STUDIES AND
TOOL OPTIMISATION
• Formaplex have produced an aluminium trial
press tool with modular inserts to allow a range
of different material thicknesses to be pressed
• LMAT will carry out cure distortion studies on
flat and angled component sections made using
Cytec prepreg
• The outcomes of LMAT study will be applied to
optimise/compensate the tool surface to
achieve manufacture the final demonstration
component within geometric tolerances
ACTIVATE
(b) IMPROVE ACCURACY VIA CURE DISTORTION STUDIES AND
TOOL OPTIMISATION
Current simulation considers thermo-elastic cool-down and chemical cure shrinkage only.
ACTIVATE Sample thickness= 2 mm, Max Deflection = .7mm Volumetric cure shrinkage was assumed to be 5% Max Deflection = 0.7mm
• LMAT FE solver expanded to include layered elements (20 noded brick & wedge)
• Phase transition model added to account for cure shrinkage in the rubbery state and thermal contraction in the glassy state
Main mirror
Reference mirror
Composite specimen
Wire clip
Location of the thermocouple
Laser pointers
Reflected laser beam
(c) AUTOMATED ANGLE / CROSS PLYING OF MULTI LAYER
FORMATS
ACTIVATE - Affordable composites for high volume manufacturing of automotive structures
Gudel UK have designed a pick and place end-effector for automated lamination Cytec will have a 2600mm wide cutting machine that will be supplied by Assyst Bullmer