Fully Automated Preform Production of Complex Geometry CFRP Parts using Fiber-Patch-Preforming Technology

MANZ AG FULLY AUTOMATED PREFORM PRODUCTION OF COMPLEX GEOMETRY

CFRP PARTS USING FIBER-PATCH-PREFORMING TECHNOLOGY

JUNE 25th, 2014 / MARTIN STEYER

2011-07 2

MARKET TRENDS

COST VIEW FRP-PRODUCTION

3D-FPP - FIBRE PATCH PREFORMING

FIBER-PATCH-PREFORMING

STRUCTURE

1

2011-07 3

Sports / Leisure

Indicators for a Growing FRP-Market:

BMW founds a new brand »BMW i«

and built up a carbon fiber production plant

Joint ventures between BMW-SGL Carbon,

Daimler-Toray and Audi-Voith

German government supports

FRP-development with 300 Mio. €

MARKET TRENDS

Aerospace

E-Cars

[Quelle: BMW, Madzda, Porsche, Mercedes, Fiberglastechnik]

Reasons for FRP-Use in Automotive Industry

Reducing fuel/ energy consumption (1 liter car VW)

Increasing range (electric vehicles)

Increasing crash-behavior (Audi A8 frontend)

Increasing driving dynamics (Porsche GT 3)

Design possibilities (7er BMW trunk lid)

FRP – meets serial production!?

Leaf spring Mercedes Sprinter

Cardan shaft

Monocoque Porsche GT3


2011-07 4

Requirements on serial FRP-parts

Quality/ performance requirements

Stresses

Crash

Geometry

Surface finish

MARKET TRENDS

High load capacity

Best crash behavior

Good formability

Up to class-A finish

New cost efficient processes need to be developed

Costs

Personal costs

Material costs

Process costs

High level of manual work

High costs for carbon fiber

Long cycle times


2011-07 5

MARKET TRENDS


3D-FPP - FIBER PATCH PREFORMING

STRUCTURE

2


2011-07 6

Cost Structure of High Quantity FRP-Parts (Example Saddle)

Number of items 20.000

Write off time (5 %) 5 Year

Personal costs 40.000 €/Year

Number of shifts 1 (8 h)

Machine availability 90 %

Etc. …

1

2

3

4

Material costs Personal costs

Variable costs

(energy, maintain, etc.)

Investment costs

Shares of Production Costs

45% 28%

18% 9%


Material price

Material consumption

1

2

Automation 3


2011-07 7

Cost Structure of High Quantity FRP-Parts (Example Saddle)

Number of items 100.000

Write off time (5%) 5 Year

Personal costs 40.000 €/ Year

Number of shifts 3 (8 h)

Machine availability 90 %

Etc. …

COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING

Shares of Production Costs

Personal costs

4 %

Variable costs

2 %

Investment costs

4 %

90 %

Material costs

Material price

Material consumption

1

2

2011-07 8

Material Efficient Reliable processes with low scrap rates

Low level of waste

Material saving processes

Material saving product design

(load optimized laminate design)

High Level of Automation Short cycle time

Cost effective systems

Cost efficient tools/ molds

Saving Variable Costs Energy effective processes

Robust systems (maintain)

Processes with low operational material consumption

Cost Effective FRP-Processes

for Serial Production

COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING

2011-07 9

Fiber/matrix production

Pre impregnation

Cutting

Handling

Transport/logistics

Pick and place

Automated preforming/ draping

Bindered preforming

Organo sheet preforming

Pre consolidation

Mold loading

Press/injection (RTM) (consolidation)

Tool and die manufacturing

Press production

Demolding and storing

Manz Production Systems and Processes within the FRP Manufacturing Chain:

US

P

Pre

form

ing

FRP-PROCESS CHAIN FIBER-PATCH-PREFORMING

2011-07 10

MARKET TRENDS


3D-FPP - FIBER PATCH PREFORMING

STRUCTURE

3


2011-07 11

3D-FPP - Demonstrated on a Saddle

3D-FPP - NEW PREFORM TECHNOLOGY

Production process for small FRP-parts

Parts with highest light weight potential

Material efficient

Fully automated process

Short cycle time

High flexibility

Licensed by Airbus


2011-07 12

Process

simulation

3D laminat

placement

CAD model

& load case

Resin injection

& cross linking

Load optimized

3D-FRP-part

Optimized product

design and fiber

architecture

SOWEMA- Software-, Werkzeug- und Maschinenentwicklung für eine

vollautomatische und geschlossene Leichtbau-Fertigungskette


3D-FPP - NEW PREFORM TECHNOLOGY

Video

2011-07 13


3D FPP - NEW PREFORM TECHNOLOGY

2011-07 15

Standard tailored fabrics More than 30% material saving against

standard processes

A A A

A-A

A B B

B-B

Material saving area

COST SAVING

Material consumption 2


Load optimized

fiber orientation

Load optimized

laminate thickness

Undulation-free

fiber orientation

Near optimal

laminate build up

2011-07 16

Less waste than 5 % of carbon fiber More waste than 30 % of carbon fiber

Low level of waste (near-net-shape)


COST SAVING

Material consumption 2

2011-07 17

Material Efficient Reliable processes with low scrap rates

Low level of waste

Material saving processes

Material saving product design

(load optimized laminate design)

High Level of Automation Short cycle time

Cost effective systems

Cost efficient tools/ molds

Saving Variable Costs Energy effective processes

Robust systems (maintain)

Processes with low operational material consumption

Cost Effective FRP-Processes

for Serial Production


FPP – COST VIEW

2011-07 18

Local reinforcements

(window frame, hole reinforcements, etc.)

Shell structures

(saddles, wheels, motor cover, etc)

Sub laminates

(aircraft stringers, clips, etc.)

FPP

flexible process


FPP - FIBER PATCH PREFORMING

2011-07 19

THANK YOU TO:

FPP - FIBER PATCH PREFORMING

Federal Ministry of

Education and

Research (BMBF)

for supporting the

»SOWEMA«

and the

»BIOTEX«

project

European Commission

for supporting the

»IMAC-PRO« project

And all project partners


Process &

machine

development

User

Software

development

Engineering

Fully Automated Preform Production of Complex Geometry CFRP Parts using Fiber-Patch-Preforming Technology