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CLIQUEZ POUR MODIFIER LE STYLE DU

TITRE

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CLIQUEZ POUR MODIFIER LE STYLE DU

TITRE

SUMMARY

I.

Company Profile

II.

Current robotic fiber placement

III.

Thermosets and Aerospace Applications

IV. Thermoplastics and Dry Fibers

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CLIQUEZ POUR MODIFIER LE STYLE DU

TITRE

SUMMARY

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CLIQUEZ POUR MODIFIER LE STYLE DU

TITRE

F

RANCE

F

RANCE

C

ANADA

C

ANADA

G

G

ERMANYERMANY

U

K

U

K

F

RANCE

C

ANADA

G

ERMANY

U

K

I - COMPANY PROFILE



Founded in 2001, French independent company, worldwide presence:

- Headquarter in Lorient with production, engineering, customer support,

software development (3500m² facility)

- approx. 100 staff and 4 subsidiaries (local presence)



Skilled in composites, robotics and software development



ISO 9001 certification since October 2010



20 worldwide patents (130 applications) on AFP systems, appli. & algorithms

Few of our references (35 Machines sold since 2006):

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CLIQUEZ POUR MODIFIER LE STYLE DU

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SUMMARY

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Fuselage Panel 25KG/H

Video Panel wave 2

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Fiber placement machine based on machine tool

Special machine-tool based systems



High investment and running costs



Not adapted to complex parts

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Robotic Automated Fiber Placement

Single tensioning device

Multiwinch

©

Flexible feeding tubes

Creel

Mould loading device

Compact Head



Head for 8/16/32 x ¼‘‘ or 8 x 1/8‘‘



Thermoset, thermoplastic, dry fiber



Heating: IR & Laser



Independent Cut & Feed on the fly



v

max

= 1 m/s

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Manual and automatic sectorization of plies

Tapes and fibers generation: short fibers management(chamfer,

bat ear, bird beak).

Tape split and slit.

Manual and automatic extension or reduction of fiber length.

Gap-overlap definition

Geometry analysis (fibre angular deviation, roller compaction…)

FEA export of fiber simulation to FEA software

(Nastran, Abaqus, Samcef)

Mesh mapping between AFP surface and structural FEA mesh

Machine set-up

Strategies definition



Software: Design simulation

II – Current robotic fiber placement

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Material able to be processed in robot AFP

Source : Toho Tenax

Packaging

Stiffness

Forming T°

Thermoset

Large spools

Medium

Required

tackiness

50°C/120°F

Dry fiber

0% to 5% resin

Spools

Very low

Binder activation

80°to 180°C

(176°F to 350°F)

Thermoplastics

Casset

Very high

180°C to 340°C

(350°F to 650°F)

FIBER

STORAGE

FIBER

FEEDING

FIBER

DELIVERY

1

2

3

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No scrap thanks to independent cutting and feeding of each fiber

Repeatability

Traceability

Productivity 1m/s

(fuselage panels)

Improved H&S for operators VS hand layup , No foreign object

Full simulation and off-line programming

II – Current robotic fiber placement

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No scrap when cut-outs

Inserts and variable thickness

Steering

High mechanical properties due to continuous fiber and curved path following main

stress



Mains benefits

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SUMMARY

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OML LAYUP

BOMBARDIER

C-Series AFT

Fuselage

AIRBUS A350 Main Landing Gear Doors

SAFRAN AIRCELLE Production of

Inner Fixed Structure for a jet engine

thrust reverser

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Vidéo nacelle



Sandwich-structured composite

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IML LAYUP

SABCA flap track fairing

Layup of complex IML parts and transfer on OML tool

for curing

Spar layup capability with Coriolis patented “corner

path technology” allowing accurate deposition and

compaction around corners

CORIOLIS Spar layup

CORIOLIS “corner path device”

• Sharp edges

• Ply drop-off

• Ramps

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SUMMARY

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Laser optic Optic Fiber

• Coriolis machine well designed to guide stiff tows (thermoplastic cannot be

steered over small radius)

• Challenge is the management of the key processing parameters



What need to be changed to process other materials?

• Standard Coriolis machine is used

• Dedicated roller (laser)

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Stabilized dry fiber and thermoplastic key parameters

Process parameters:

Activation:

ACTIVATION

Laser (80° < T°C < 360°C) at speed>= 1 m/s

QUALITY

CONTROL

IR imaging

v

P

Peel

Tension

stabilised

binder

Heat

activated

binder

Video

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Future of Thermoplastic with AFP

Influencing factors for the future of thermoplastic:

Future :

-

Combination with other process

-

In situ consolidation?

Pros

Cons

- Recycling

- No curing cycle

- No shelf life

- No cooling system for the fiber

- Heat source (Laser)

- Cost of row materials

- First ply adherence

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Direct roving preferred to slit tape to reduce costs, reduce fiber fuzz and improve

mechanical properties

Consolidation between plies: matrix or binder formulation adapted to improve

activation at low temperature

First ply adherence should not reduce layup speed but allow easy part release

Fiber stiffness and cohesion to prevent bulking & shearing of the preform during

fast layup, even for thick laminates or curved paths

Material architecture optimized for forming and resin transfer



CHALLENGE: MATERIAL

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v

P

Peel

Tension

stabilised

binder

Heat

activated

binder

IV – Thermoplastics and Dry Fibers

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Research programs dedicated to TP and dry fiber

• Aeronautics

Defi Composites (nacels, dry fiber placement) with Safran and Airbus

Flash_TP / TAPAS (Thermoplastic) with EADS, Airbus and Astrium 12

ADVITAC and Ecowingbox (regional jet) with Daher, Embraer

IMPALA (France) with Dassault Aviation, Daher, EADS,

• Automotive

PRESCHE (Germany) with AUDI

DEMOS (France) with Faurecia, automotive parts

• Wind energy

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Research program ADVITAC

ADVITAC “Advanced Integrated Composite Tailcone”

Design a lightweight multi-layer/multifunction and smart composite tailcone in a

fasteners-less fully integrated structure.

Coriolis Composites central focus was to manufacture the skin of the tailcone using

an innovative fibre placement technology using carbon dry fiber.

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Video advitac



Research program ADVITAC

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SUMMARY

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Robotic AFP system provides:

Simple robotic system

Efficient layup with compact head design + fiber feeding mechanism

Accuracy & repeatability

Minimal scrap (<5%)

New materials processing:

Almost all parts done with thermosets materials could be done with thermoplastic

with Coriolis AFP robot



In-depth material understanding required



Machine performance and material development have to progress in parallel

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CLIQUEZ POUR MODIFIER LE STYLE DU

TITRE

Contact:

Sales director: Davy LEBOUCHER (

davy.leboucher@coriolis-composites.com

)

Chinese agent: James PENG (

james.peng@ateq.com.cn

)

Thank you for your

attention

References

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