CMTS (Continuous Multi-Tow Shearing) for High-Volume Production of - - PowerPoint PPT Presentation

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 Shearing Evangelos Zympeloudis

Birth of Engineering Composites

Cellulose Lignin Hemicellulose

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Composite Materials

Composite = Matrix + Reinforcement

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

High-End Applications

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Where are we now?

[1] www.airbus.com [1] [1]

6/19

CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

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)

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Geometry determines method

MAG Cincinnati (USA) MTorres (Spain)

ATL AFP

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Where are we now?

[1] www.airbus.com [1] [1]

9/19

CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

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

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Manufacturing for Design

Bone Cartilage

Exploit Anisotropy in Composites Design – Escape Straight Fibre Paradigm

New Manufacturing Methods = New Possibilities

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Tow Steering

T steer Sh

[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

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Could this be a step closer?

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

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]

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Continuous Tow Shearing (CTS)

• Minimum steering radius  30 mm for 8 mm wide tow
• Decoupling of width and minimum steering radius

[5]

CTS AFP/ATL

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

[6]

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Continuous Multi Tow Shearing (CMTS)

Tape laying machine capable of

• High Quality steered laminates
• High Production Rates.

Compaction Shoe

Pinch Device

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

for 90 mm wide tape

Operation of CMTS Prototype

Steering Radius: 300 mm

• cf. ATL: 6000 mm for 150 mm wide tape

AFP: 630 mm for 3.175 mm wide tow

for 90 mm wide tape

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Material Parameters affect Quality

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

50 110 170 230 Percentage of Resin Area (%) X Position (mm)

Resin Pocket Areas vs Position

Tows 1-10 Tows 11-30 Tows 31-40

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CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

A Glimpse to the Future

• Nature has mastered the design of composites
• Escape the straight fibre paradigm
• Tow Steering
• Complex shapes
• Optimised Designs
• Continuous Multi Tow Shearing
• Improve structural efficiency
• Meet productivity needs

19/19

CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

Thank you for your Attention!

• Supported by:
• Supervisors:

– B.C. Eric Kim – Paul Weaver – Kevin Potter