007 FKV Applications 2 WS0708

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Kindervater FKV_2007_08_Applications Applications-2: 52

Anwendungen von FVW (Teil2)

Christof Kindervater

Vorlesung WS 2007/2008DLR Stuttgart, Institut für Bauweisen- und

Konstruktionsforschung




Composite rotor blades of wind energy converters

Blade hub connection

with loops

DEBRA

• 2-piece rotor blades

• GFRP rovings and

fabrics in hand lay up

• rotor diameter 25 m

• Mass of one rotor:

320 kg

• performance: 100 kW




Composite fan blades of DNW wind tunnel

CFRP blades

• high specific stiffness:> high eigen frequenzcies > high RPM

• long fatigue life of CFRP

• good contour quality of blades > high aerodynamic efficiency




Composite applications in sporting goods

• composite replace metal and wood

• use of all kind of f ibre and matrixsystems (the newer the better due toprestige!)

• high vibration damping

• low weight combined with highmechanical performance

• not sensitive to moisture (comparedto wood!)

• high design flexibility and trimmingcapability (weight, stiffness etc.)




Composite tennis rackets

2 frame design for vibration damping

• wet lamination with carbon braidings,

2-rac

• hand lay up mass production with

prepreg and heated steel moulds

(6-8 bar, 160°C, 3-10 min.)




Composite bicycle frames

Hercules monocoque

• composite conform design without

metal fittings

• sandwich design with honeycomb core

• low weight (9,5 kg), high stiffness

• CFRP disc wheels

• high prestige

Composite bike frame

• tubes with hybrid braidings

(80%CFRP/20%GFRP)

• good riding comfort

• light weight, no corrosion

• price comparable with steel frames




Composite Applications cont´d

Ship building• applications since 50 years

• 20 years of guarantee

• use of glass mats and fabrics and polyester resins (price!),

short construction times

• local reinforcements with CFRP and aramid

• monolithic and sandwich designs

• corrosion resistance (salt water)• GFRP submarines, non magnetic

• high performance racing yachts




Composite ship building applications

Mine sweeper

Ship hull manufacturing

• hand lamination/resin infusion with polyester

resins (price!)

• sandwich design

• low weight, low cost, saltwater resistance





Vehicle technology

• wide application of composites• preferred use of low cost composites with glass fibre

reinforcements

• high tech applications of carbon fibres in racing cars (chassis

and crash cones)

• hand-lay-up, fibre spraying, pressing, filament winding, resininfusion and autoclave manufacturing technique

• low weight results in fuel savings and other synergetic effects

(small engine, single axle, small ti res etc.)

• good damping and corrosion resistance

• structural examples: large body parts, drive shafts, springsand torsion rods, bumper systems, chassis frames, train

coach structures and bumpers




GFRP leaf spring for trucks

• series production for special

trucks (fire fighter vehicles)

• UD-prepreg with epoxy matrix• springs are cut from wide plates

into the proper width

• 60% weight saving

• better elastic energy storage dueto high strength and low E-

modulus of GFRP

• uncri tical damage progression

• high fatigue life

• good acoustic properties




Fact 4 prototype of sport racing car:

• car body: CFRP and aramid sandwich

• very stiff design with IMS carbon fibres

• good cost relation for prototype

manufacturing

BMW Z1 floor structure:

• sandwich design with GFRP face

sheets > self supporting design• small number series production




FKV im Automobilbau

Porsche Carrera GT:

• Gesamtstückzahl: 1500 (ca. 2 Jahre)• CFK-Prepreg (Handarbeit)

• Keine Crashperformance in der CFK-Struktur

BMW Z22:

• Gewichtsvorteil gesamt: 33%

• Kraftstoffersparnis: 45%

• Crashperformance entspricht 528iA

durch Al-Unterkonstruktion

Mercedes SLR McLaren:

• Front-/Heckstruktur, Fahrgast-zelle,Flügeltüren und Motorhaube ausCFK

• CFK- Front-Crahstruktur (CFK-Längsträger: 3,4 kg)

• Motorträger aus Al-Sandguss






Composite racing sport applications

Racing car CFRP monocoque:

• low weight, high torsion

stiffness

• sandwich or integrally stiffened

• CFRP energy absorbers

Racing motor bike:

• CFRP and GFRP application more than 10

years

• manufacturing: pressing, filament winding, fibre

spraying, autoclave

• parts: cowlings, frames, wheels, springs

• GFRP parts for series production




CFRP application in CLT DTM 2000

CLK 2000 CFRP front structure:

• spoiler and body parts

• venting system

• front crash box

Quelle: HWA




Entwicklung der FKV-Crashboxenfür Mercedes-CLK bei DTM 2000

Vergleich von num. Simulation mit realem Crashtest

Partner/ Auf traggeber: HWA GmbH, Affalterbach

Nachweistest der vorderen Crashbox

v0=13 m/s, m=1200 kg

Simulation der vorderen

Crashbox




Steering column crash absorber

Kevlar absorber element;

Serienelement in GFKSerienanwendung in 7er und 5er BMW-Lenkmodul




Composite applications in vehicle and safety

technology

Sports car seat:

• very low weight

• resin injection manufacturing

Ballistic protection helmet:

• same weight as steel helmet provides50% higher protection

• low weight results in high wearing comfort

and low neck loading > less fatigue




Neoplan Metroliner - a composite bus

• small series production (100 buses)

• vacuum assisted curing with CFRPand GFRP sandwich (50 mm and 40

mm foam cores)

• 40% weight saving > smaller engine

>lighter axles >lighter/less tires

>lower fuel

• less tire and brake tearing

• disadvantages:

- high noise level with prototypes

- 25% higher manufacturing cost

compared to conventional steel frame

design




Neoplan Metroliner structural assemblage

Structural modules before

bonding assemblage

Steel fixtures for adhesive bonding ofMetroliner modules




CFRP engine parts

• Mass reduction of oscillating

parts > higher performance

• CFRP rovings and fabrics

with epoxy Novolack matrix

CFRP part mass mass reduction

• bolt 107 g 60%

• piston rod 270 g 65%

• crank shaft 3010 g 50%

• valve rod 30%

• valve lever 53%




Composite train applications

Train coach design conceptTrain coach manufacturing

• sandwich structure in tape windingtechnique

• integration of venting /electrical

system in foam core

• highly automated processQuelle: Schindler Waggon




Series application since 1997

ICT crash absorber:

4 GFRP absorber (fabric/epoxy matrix)

4 Load: 750 kN, stroke: 300 mm

Crash sequence:

4 impact mass: 80 t

4 impact velocity: 4 m/s

AVI

ICT - Pufferabsorber




Composite applications in civil engineering

GFRP pedestrian bridge:

• Length 120 m, main span: 63 m

• GFRP polyester resin

• pultrusion profiles are adhesive

bonded at construction site

CFRP and DYNEEMA cables:

• less weight compared to steel

• corrosion resistant and low maintenance cost

•more design flexibility with concrete structures,

higher possible span with bridges

• DYNEEMA cables do float




Radio telescope La Silla (Chile) at 2400 m altitude

• frame work with CFRP tubes

• mirror surface with CFRP plateswith a tolerance of +/-45μm

• low thermal expansion

coefficient and high stiffness

> non -uniform sun radiation

> high wind speeds up to 200

km/h and 10 cm ice accretion

• no protection radome necessary




Composite pioneer bridge

• metal structure with local

reinforcement with CFRP

profiles

• stiff and light design

> good handling

> no corrosion





Medicine technology

• price is not driving factor

• light weight and stiff structures

• primary use of carbon fibres

• long life cycles due to high fatigue performance• no corrosion

• X-ray transparency

• human body compatibility

• examples: arm and leg prothesis, orthesis, implants, medical

tools/equipment, x-ray tables




Composite medicine technology applications (1)

Composite wheel chair:

• CFRP frame and plates

• resin injection with Injectex fabric

• mass: 6,5 kg

• price comparable with titanium

X-ray table:

• high stiffness for good positioningaccuracy

• x-ray transparency > low radiation

loading for the patient





Stereotaxie apparatus:

• application for Kernspin tomography

• CFRP/epoxy ring provides highstiffness for good positioning accuracy

of instruments

• metal parts would not allow

diagnosis due to Eddy currencies

Artificial hip joint implants:

• good human body compatibility

• implant stiffness can be adapted tonatural bone properties





CFRP leg prothesis:

• provides natural walking feeling

• light with good damping

Lower leg prothesis:

• GFRP leaf springs

• provides natural walking and spring

damping behaviour





Mechanical engineering, plants and facilit ies

• Low weight and mass inertia in highly accelerated and

decelerated parts

• high vibration strength and damping

• higher revolution speeds with rotating parts, shorter

machining costs• low maintenance

• simple and application oriented design

• good chemical resistance




Composite robotics applications

GFRP robotic arm:

• filament winding with integration of metal

bearings > no later machining

• re-useable segmented winding mandrel• 65% weight reduction

> 13% higher max. acceleration

> 34% higher max. pay load

compared to metal design

CFRP manipulator arm (ROTEX

ground experiment):

• weight 212 g

• failure load 54 kg lever loading

• axle distance: 340 mm

• max torsion: 123 Nm




Composite applications in weaving machines

Head of thread manipulator arm:

• CFRP leaf springs

• high fatigue life

• low mass in highly oscillating andaccelerated part > low transmission power

and faster machines

CFRP thread manipulator arm:

• CFRP thermoplastic matrix(PEEK)

• high vibration damping

• high accuracy positioning




Composite applications in mechanical engineering

Grinding table of cog-wheel gr inding

machine:

• low weight and high stiffness reducesmachining time

• mass: 33 kg, metal cast: 100 kg

• Frequency: 3 Hz

CFRP machine drive shaft:

• filament wound with metal fittings

• almost zero thermal expansion

• higher dynamic strength combined

with less mass provides higher RPM




Composite tank and vessel applications

GFRP loop fixture of low temperature gas tank

• low thermal conductivity and high strength

GFRP containers:

• filament wound with glass

and polyester resin

• chemical resistant• suited for wine and juices

etc.

Smoke gas cleaning

towers:

• filament wound GFRP

tubes with VE resin

• diameter up to 7 m

> on-site manufacturing





Electro technology/electronics

• electrical insulation with glass fibres laminates

• good acoustic sound quality and damping in hi-fi equipment




Composite electric/electronic applications

GFRP plate for electronics:

•electrical insulation of GFRP

• glass fabric/epoxy resin

Electric cable

suspender:

• electr. insulation

and high strength• GFRP rovings

spiral wound

CFRP HIFI

equipment:

• good sound

quality

• good vibration

damping




Composite Sousaphone

• low weight: 7,2 kg> can be carried and played

by kids and women

• damage tolerant GFRP

> no change of sound quality

• easy colouring and painting




CFK-Violine

• Unempfindlich

gegenüber Witterungs-

einflüssen

• Exzellente Ansprache

• Große Dynamik

• AusgewogenesKlangbild

• Präzises und ausdruck-

starkes Spiel

Quelle: Diamo Violins

Documents

007 FKV Applications 2 WS0708