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A HOLISTIC APPROACH TO QUALITY MANAGEMENT FOR COMPOSITE FORMING PROCESSES Dr. Farbod Nezami June 2016 Composite Forming: Reliable, fast, effective, but Geometry Process Source: Airbus, Boeing, ETZ, Daimler Complex shaped geometries

SLIDE 1

A HOLISTIC APPROACH TO QUALITY MANAGEMENT FOR COMPOSITE FORMING PROCESSES

June 2016

Dr. Farbod Nezami

SLIDE 2

28.09.2017 | 2 Fuhr | Nezami | Schierle

Composite Forming: Reliable, fast, effective, but…

Source: Airbus, Boeing, ETZ, Daimler

High lot size
Cost sensible
Complex shaped geometries
Small sectioned parts
Packaging- & design demands

Geometry Process Fast forming processes What to do about quality? How can we improve the quality of preforms with an holistic quality approach?

1.

Parts free of wrinkles and reduction of fiber distortions (“waviness”)

2.

Influencing of fiber orientation and shear angles

3.

Assess the resulting mechanics

4.

Validate our approach?

SLIDE 3

28.09.2017 | 3 Fuhr | Nezami | Schierle

The Complexity of Composite Forming

Textiles show specific forming modes and characteristics.
Complex Geometries consisting of radii, curvature, edges.
Formability can be influenced by Process factors too.
These interactions define the resulting Mechanics of the structure.

 Every development has to be regarded as a holistic system of all aspects

Textiles Geometry Process

Mechanics

SLIDE 4

28.09.2017 | 4 Fuhr | Nezami | Schierle

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Draping simulation Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

SLIDE 5

28.09.2017 | 5 Fuhr | Nezami | Schierle

Material characterization with process induced factors: Shear-Tension Coupling B A

Membrane tension No wrinkles at 55° Tension free Wrinkles at 55°

SLIDE 6

28.09.2017 | 6 Fuhr | Nezami | Schierle

Material characterization with process induced factors: Fiber waviness due to interactions

Forming Limit Diagram

Fiber waviness In-plane damage

SLIDE 7

28.09.2017 | 7 Fuhr | Nezami | Schierle

Definition of a Forming Limit Diagram for Interaction Defects

Textiles Geometry Process

SLIDE 8

28.09.2017 | 8 Fuhr | Nezami | Schierle

Recent developments in prediction of fiber waviness

The first chapter of the quality approach showed us that:

– There is an interlink between tension (process) and wrinkling (textile) – There is an interaction of layers towards each other which can cause fiber waviness

Draping simulation can be used to investigate the risk of wrinkles and fiber waviness

SLIDE 9

28.09.2017 | 9 Fuhr | Nezami | Schierle

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

SLIDE 10

28.09.2017 | 10 Fuhr | Nezami | Schierle

Integration of forming defects of composite forming to FEA analysis

Nezami, Fuhr, Schierle, Cherif, Middendorf: Holistic development of high quality composite parts based on automated preforming in JEC magazine no. 103, March 2016, Special JEC World

3D Plot of fiber orientation due to forming FEA modelling Analysis of forming effects

Draping simulation

SLIDE 11

28.09.2017 | 11 Fuhr | Nezami | Schierle

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

SLIDE 12

28.09.2017 | 12 Fuhr | Nezami | Schierle

Integration of previous steps into process development

Reduction of interaction force and fiber waviness by oscillations

Mechanical actuators

Reduction of wrinkling due to local application

f tensile forces

SLIDE 13

28.09.2017 | 13 Fuhr | Nezami | Schierle

Application: Mercedes-Benz AMG Backlid

Cut-out optimization and ply clamping Transfer to active interlayers Multilayer draping with active interlayers

Orientation 0° Orientation 45°

Clamping Cut / Dart Clamping

Different material draw-in and clamping necessary!

0/90° top layer

Homogenous Blank Holder Force Ply-specific clamping

Piezo actuators for oscillations

Reduction of the size of

wrinkles by 81,5%

Complete suppression
f interaction based

defects

SLIDE 14

28.09.2017 | 14 Fuhr | Nezami | Schierle

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

SLIDE 15

28.09.2017 | 15 Fuhr | Nezami | Schierle

Validation and Assessment of Measures by Optical Fiber Measurement System

1 Local Analysis

Definition of critical spots

2 Definition of robot coordinates Analysis of

Fiber orientations
Gaps
Validation of draping simulation

4

VALIDATION & ASSESSMENT

3 Capturing

SLIDE 16

28.09.2017 | 16 Fuhr | Nezami | Schierle

Conclusions

To increase quality of parts being produced by composite forming an holistic approach is necessary

as interlinks of domains drive overall quality

Early stage material characterization can help to identify dominant quality drivers
In preforming it was found that wrinkles can be suppressed by local tensioning, but risk of

interaction defects like fiber waviness can increase hereby. Therefore reduction of normal contact forces is necessary.

This was realized by the utilization of active interlayers which can actively control tensioning and

reduce interlayer friction by oscillations

Optical fiber measurement systems were applied to validate the results of draping simulations and

A HOLISTIC APPROACH TO QUALITY MANAGEMENT FOR COMPOSITE FORMING PROCESSES

June 2016

Composite Forming: Reliable, fast, effective, but…

Source: Airbus, Boeing, ETZ, Daimler

Geometry Process Fast forming processes What to do about quality? How can we improve the quality of preforms with an holistic quality approach?

1.

Parts free of wrinkles and reduction of fiber distortions (“waviness”)

2.

Influencing of fiber orientation and shear angles

3.

Assess the resulting mechanics

4.

Validate our approach?

The Complexity of Composite Forming

 Every development has to be regarded as a holistic system of all aspects

Textiles Geometry Process

Mechanics

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Draping simulation Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

Material characterization with process induced factors: Shear-Tension Coupling B A

Membrane tension No wrinkles at 55° Tension free Wrinkles at 55°

Material characterization with process induced factors: Fiber waviness due to interactions

Forming Limit Diagram

Fiber waviness In-plane damage

Definition of a Forming Limit Diagram for Interaction Defects

Textiles Geometry Process

Recent developments in prediction of fiber waviness

– There is an interlink between tension (process) and wrinkling (textile) – There is an interaction of layers towards each other which can cause fiber waviness

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

Integration of forming defects of composite forming to FEA analysis

3D Plot of fiber orientation due to forming FEA modelling Analysis of forming effects

Draping simulation

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

Integration of previous steps into process development

Reduction of interaction force and fiber waviness by oscillations

Mechanical actuators

Reduction of wrinkling due to local application

Application: Mercedes-Benz AMG Backlid

Cut-out optimization and ply clamping Transfer to active interlayers Multilayer draping with active interlayers

Orientation 0° Orientation 45°

Clamping Cut / Dart Clamping

Different material draw-in and clamping necessary!

0/90° top layer

Homogenous Blank Holder Force Ply-specific clamping

Piezo actuators for oscillations

wrinkles by 81,5%

defects

An Holistic Quality Approach to Preforming

„Planning quality“ „Realizing quality“ „Ensuring quality“ „Analysing quality“

Methods Process Selection Material Selection Process Feasibility Methods Active manipulation Automation Tool design Methods Optical analysis Non-destructive testing Quality criteria Methods Composite FEA Sensitivity studies Process factors

Textiles & Geometry Process Validation Mechanics

Definition of local quality criteria Process optimization Draping effects

Validation and Assessment of Measures by Optical Fiber Measurement System

1 Local Analysis

Definition of critical spots

2 Definition of robot coordinates Analysis of

4

VALIDATION & ASSESSMENT

3 Capturing

Conclusions

as interlinks of domains drive overall quality

interaction defects like fiber waviness can increase hereby. Therefore reduction of normal contact forces is necessary.

reduce interlayer friction by oscillations

assess the quality improvement due to process improvements