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

CMTS (Continuous Multi-Tow Shearing) for High-Volume Production of Complex Composite Parts Evangelos Zympeloudis University of Bristol www.bris.ac.uk/composites

2/19 Birth of Engineering Composites Cellulose Hemicellulose Lignin CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

3/19 Composite Materials Composite = Matrix + Reinforcement CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

4/19 High-End Applications CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

5/19 Where are we now? [1] [1] [1] www.airbus.com CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

6/19 Aerospace Industry - Automation • AFP (Automated Fibre Placement) • ATL (Automated Tape Laying) – Narrow tows 3.2 – 12.7 mm – Wide tapes 70 -300 mm MAG Cincinnati (USA) Electroimpact (USA) CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

7/19 Geometry determines method ATL AFP MTorres (Spain) MAG Cincinnati (USA) CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

8/19 Where are we now? [1] [1] [1] www.airbus.com CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

9/19 The Quest for Structural Efficiency Stiff + Strong Weak Composite  Strong in Fibre Direction Layer Stacking  Tailor Global Stiffness We are employing composites in straight fibre arrangements CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

10/19 Manufacturing for Design Cartilage Bone Exploit Anisotropy in Composites Design – Escape Straight Fibre Paradigm New Manufacturing Methods = New Possibilities CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

11/19 Tow Steering • Lay-up on complex doubly curved moulds • Structural efficiency through variable-stiffness structures T [2] [3] steer [2] Coburn et al. 2015 [3] Chauncey Wu et al. 2009 Sh CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

12/19 Could this be a step closer? CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

13/19 Limitations of Current Technology • In plane bending of tapes  defects: [4] [5] Fibre Buckling Width affects steering abilities • 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 CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

14/19 Continuous Tow Shearing (CTS) AFP/ATL CTS [5] [6] • Minimum steering radius  30 mm for 8 mm wide tow • Decoupling of width and minimum steering radius [6] B.C. Kim et al, 2014 CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

15/19 Continuous Multi Tow Shearing (CMTS) Tape laying machine capable of Pinch Device • High Quality steered laminates • High Production Rates . Compaction Shoe CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

16/19 Operation of CMTS Prototype Steering Radius: 300 mm for 90 mm wide tape for 90 mm wide tape cf. ATL: 6000 mm for 150 mm wide tape AFP: 630 mm for 3.175 mm wide tow CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

17/19 Material Parameters affect Quality 0 Resin Pocket Areas vs Position 10.0 Tows 1-10 9.0 Percentage of Resin Area (%) Tows 11-30 8.0 Tows 31-40 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 -230 -170 -110 -50 0 50 110 170 230 X Position (mm) CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

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 CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis

19/19 Thank you for your Attention! • Supported by: • Supervisors: – B.C. Eric Kim – Paul Weaver – Kevin Potter CMTS: Continuous Multi Tow Shearing Evangelos Zympeloudis