cmts (continuous multi-tow shearing) · cmts (continuous multi-tow shearing) for high-volume...

www.bris.ac.uk/composites

CMTS (Continuous Multi-Tow Shearing)for High-Volume Production of Complex

Composite Parts

Evangelos Zympeloudis

University of Bristol

2/19

CMTS: Continuous Multi Tow ShearingEvangelos Zympeloudis

Birth of Engineering Composites

Cellulose

Lignin

Hemicellulose

3/19


Composite Materials

Composite = Matrix + Reinforcement

4/19


High-End Applications

5/19


Where are we now?

[1] www.airbus.com

[1]

[1]

6/19


Aerospace Industry - Automation

• ATL (Automated Tape Laying)

– Wide tapes 70 -300 mm

• AFP (Automated Fibre Placement)

– Narrow tows 3.2 – 12.7 mm

Electroimpact (USA)MAG Cincinnati (USA)

7/19


Geometry determines method

MAG Cincinnati (USA)MTorres (Spain)

ATL AFP

8/19


Where are we now?

[1] www.airbus.com

[1]

[1]

9/19


The Quest for Structural Efficiency

Composite Strong in Fibre Direction Layer Stacking Tailor Global Stiffness

We are employing composites in straight fibre arrangements

Stiff + Strong

Weak

10/19


Manufacturing for Design

Bone

Cartilage

Exploit Anisotropy in Composites Design – Escape Straight Fibre Paradigm

New Manufacturing Methods = New Possibilities

11/19


Tow Steering

Towsteered Shell

[2] Coburn et al. 2015 [3] Chauncey Wu et al. 2009

[2] [3]

• Lay-up on complex doubly curved moulds

• Structural efficiency through variable-stiffness structures

12/19


Could this be a step closer?

13/19


Limitations of Current Technology

• In plane bending of tapes defects:

• Minimum Steering Radius

– ATL: 6000 mm for 150 mm wide tape

– AFP: 630 mm for 3.175 mm wide tow [4]

[4] M. H. Nagelsmit et al, 2013 [5] K. D. Potter, 2009

Fibre Buckling Width affects steering abilities[4] [5]

14/19


Continuous Tow Shearing (CTS)

• Minimum steering radius 30 mm for 8 mm wide tow

• Decoupling of width and minimum steering radius

[5]

CTSAFP/ATL

[6] B.C. Kim et al, 2014

[6]

15/19


Continuous Multi Tow Shearing (CMTS)

Tape laying machine capable of

• High Quality steered laminates

• High Production Rates.CompactionShoe

Pinch Device

16/19


for 90 mm wide tape

Operation of CMTS Prototype

Steering Radius: 300 mm

cf. ATL: 6000 mm for 150 mm wide tapeAFP: 630 mm for 3.175 mm wide tow

for 90 mm wide tape

17/19


Material Parameters affect Quality

0

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

-230 -170 -110 -50 0 50 110 170 230

Percen

tag

e o

f R

esin

Area (

%)

X Position (mm)

Resin Pocket Areas vs Position

Tows 1-10

Tows 11-30

Tows 31-40

18/19


A Glimpse to the Future

o Nature has mastered the design of composites• Escape the straight fibre paradigm

o Tow Steering• Complex shapes • Optimised Designs

o Continuous Multi Tow Shearing• Improve structural efficiency• Meet productivity needs

19/19


Thank you for your Attention!

• Supported by:

• Supervisors:

– B.C. Eric Kim

– Paul Weaver

– Kevin Potter

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