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Composites technology

            Faserverbund

A number of innovative concepts for the manufacturing of FRP parts are being developed at the department for composite technologies. All phases of a real development process chain are addressed: the dimensioning of structural parts, the application of different production technologies as well as the testing of components.

The main focus lies in “preforming technologies”. This means that a near net shape, textile preform is manufactured, which then is infiltrated and cured to create an FRP part. The available technologies are:
 

  • Textile Preforming

               - Braiding technology
               - 3D sewing technology (twin-needle sewing, blind stitch sewing, tufting)
               - Tailored Fiber Placement (TFP)
               - Draping technology

  • Joining technologies, hybrid construction method
  • Sandwich technology
  • Infiltration and curing
  • Material and component testing
  • Development and evaluation of process chains
  • Automation technology

In the 21st century, economic and ecological objectives are the big driving powers behind the research and development in transport engineering. Caused by the shortage of fossil resources as well as the climate change, reduced fuel consumption and exhaust emissions become more and more important. These goals can only be achieved if the full light weight potential of fibre reinforced plastics (FRP) are utilised. This is valid both for aerospace and automotive engineering, two industrial sectors which will rapidly continue to grow in the next decades.

Research Group Braiding Technology

Braiding is one of the main competences of the composites technology group at IFB. Two braiding machines of two different sizes are available, therefore the manufacturing of braided FRP parts of a large range of diameters is possible.
In order to control both speed and orientation of the braiding mandrel, the institute uses two handling robots by KUKA Roboter GmbH. The angle of the braiding angles can be precisely adjusted, even for complex parts. Furthermore, different fibre materials can be used and combined. Hybrid fibre architectures with e.g. carbon, glass and/or aramid are possible

Research Group TFP (Tailord Fiber Placement)

Nature shows us how fibrous structures can be adapted for occurring loads. Both the geometry and the fibre orientation can be adjusted to achieve an ideal result. Common examples are trees, blades of grass and bones. TFP allows to individually place reinforcing fibres along curved load paths. Rovings are fixed on a textile surface using a sewing thread, creating a preform which is both flexible and robust.
Parts created or reinforced using this technology have an extremely high lightweight potential. The automated additive procedure offers a very good reproducibility and minimal waste of fibre material. Examples of the application of TFP are shown in the following pictures.
 

 

Tanzmaus
Abb. 1: Preform for the brake booster of a mountainbike

 

                 /fak6/ifb/img/Flechttechnik2.jpg
Abb. 2: Parabollicaly shaped antenna for an aerospace application

 

Team:
Stefan Carosella (Gruppenleiter)
Annika Ackermann
Holger Ahlborn
Markus Blandl
Patrick Böhler
Martina Bulat
Mathias Engelfried
Gerd Falk
Daniel Fernández
Julian Fial
Florian Gnädinger
Frieder Heieck
Klaus Heudorfer
Daniel Michaelis
Marko Szcesny
Benjamin Wolfinger

Projects:

TC² BaWü - Projekt "RTM CAE/CAx"

Content

The aim of the project is to create a continuous numerical modelling of new materials and structures. From the simulation of the production process to the resulting part properties, the RTM process is regared.

IFB contribution

  • Modelling and description of the draping behaviour
  • Simulation of non-destructive testing
  • Simulation of the material behaviour under static and fatigue loading
  • Modelling of failure mechanisms

Coordination

Karlsruher Institut für Technologie (KIT) - FAST

Partners

Fraunhofer Institut für Chemische Technologien (Fh ICT)
Fraunhofer Institut für Kurzzeitdynamik (Fh EMI)
Fraunhofer Institut für Werkstoffmechanik (Fh IWM)
Hochschule Esslingen (HS ES)
Hochschule Konstanz (HS-Kon)
Institut für Bauweisen und Konstruktionsforschung am DLR (DLR BK)
Institut für Textil- und Verfahrenstechnik Denkendorf (ITV)
Karlsruher Institut für Technologie (KIT) - ITCP
Uni Stuttgart - IFB

Funding

Forschungsschwerpunktprogramm Baden-Württemberg

Duration

July 2010 - July 2013

Contact

Dipl.-Ing. Frank Härtel

 

KITe hyLITE PLUS

Content

  1. Development of new technologies for hybrid lightweight design
  2. Development of lightweight structures, preferably with composite materials
  3. Compilation of results from the three core topics: methodology, materials, production processes

IFB contribution

  • Textile technology
  • Preforming

Coordination

KITe hyLITE Plus (Koordinator)

Partners

ICT Fraunhofer, IWM Fraunhofer, LBF Fraunhofer, FAST, IAM-WK, wbk, IPEK

Funding

EU

Duration

October 2009 – September 2013

Contact

Dipl.-Ing. Virginia Bozsak

 

ProCaV - Produktive und schädigungsarme Laserbearbeitung von Carbonfaser-Verbundwerkstoffen

Content

  • Development of basics in production technologies using LASER
  • Online diagnostics to monitor the processing progress and the degradation depth
  • Analysis of the scalability of the processes

IFB contribution

  • Development of testing methods to validate the machining of laser-cut carbon fibres
  • Coordination of the testing program within the project

Coordination

TRUMPF GmbH + Co. KG, Ditzingen

Partners

Audi AG - Ingolstadt, Daimler AG - Stuttgart, Porsche Engineering Group GmbH - Weissach, TRUMPF Laser- und Systemtechnik GmbH - Ditzingen, GFH GmbH - Deggendorf, IFSW - Universität Stuttgart, IFB - Universität Stuttgart

Funding

BMBF

Duration

December 2011 - November 2014

Contact

Dipl.-Ing. T. Prieß

 

 

 

 

 

 

 

 

 

 

 

 

 

LOWFLIP - Low Cost Flexible Integrated Composite Process


Content

  • Development of a manufacturing process for structural CFRP parts from different transport sectors (aviation, automotive, cargo)
  • Development of new technologies with a low level of invest, also suitable for SMEs
  • Installation of an automated manufacturing process with high productivity and material quality
  • Development of a new prepreg material for out-of-autoclave processes to shorten cycle times
  • Development of a new laying head system for large structural parts and a multifunctional pick & place process for smaller, complex parts

IFB contribution

  • Project coordination
  • Development of a laying head system for the fast, three-dimensional fiber placement of large structural components
  • Installation of an automated prototype cell for demonstrator manufacturing together with the partners
  • Material and component testing
  • Simulation and testing of draping behavior

Coordination

IFB

Partners

  • Fundacion Tecnalia Research & Innovation
  • Aernnova Engineering Solutions Iberica SA
  • Carbures Europe SA
  • Kögel Trailer GmbH & Co KG
  • ALPEX Technologies GmbH, SGL Carbon GmbH
  • Mecas ESI SRO, FILL GmbH
  • ALMA Consulting Group SAS

Funding

FP7

Duration

October 2013 until October 2016

Contact

Dipl.-Ing. Frieder Heieck

http://www.lowflip.eu/ (Website under construction)