HP- RTM Process Advancements

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HP- RTM – Process Advancements

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01 | 2010 – Seite 2

High Pressure Resin Transfer Molding – Process

Advancements

Matthias Graf Dieffenbacher GmbH+Co. KG, Heilbronner Str. 20, 75031 Eppingen, Germany,

[email protected] Erich Fries

Josef Renkl Krauss Maffei Technologies GmbH

Krauss-Maffei-Straße 2, 80997 München [email protected]

Prof.Dr. Frank Henning Raman Chaudhari

Bernd Thoma Fraunhofer ICT, Joseph-von-Fraunhofer-Str. 7, 76327 Pfinztal, Germany,

[email protected]

10th ACCE, 15-16. Sept 2010, Troy (MI)

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RTM Material Advantages

RTM Technology and Applications

Cooperation Dieffenbacher – Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining

Content

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01 | 2010 – Seite 4

RTM Material Advantages

Cooperation Dieffenbacher – Krauss Maffei RTM Preforming

RTM Dosing Systems RTM Tool Design

RTM Press Concept RTM Machining

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2.

• Self cleaning Mixing head

• Stable temperature control inside

the metering machine up to 120°C

2. Stable Process High repeatability 3. High Productivity 1. Excellent Part properties 3.

• relatively short cycle times

compared to LP process

• IMP Possible

• high degree of automating possible

1.

• distinguished mechanical properties –

bidirectional

• high surface quality

• paintable on both part sides

RTM

Unbeatable combination of properties

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01 | 2010 – Seite 6

Fiber contents up to 70 weight percentage with RTM Material:

• EP Epoxy or Polyurethane resin • Glass, Carbon fibers

Fiber length:

• Start length 50 mm - ∞

• Length in part 50 mm - ∞ Benefit:

• Defined fiber orientation • Unsolvable binder

• High mechanical properties (directional) • Low specific weight

• High fiber contents

Typical application

_{Utility vehicles and trucks} _{Aircraft & helicopter (Carbon)} _{Optical (visual) parts}

Unbeatable combination of properties

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RTM Technology and Applications

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01 | 2010 – Seite 8

Semi finished cuts Preform _{Preform placement} on mold

Cured component Resin

Apply vacuum; inject resin; impregnation and curing

1. Vacuum infusion process - VIP

Vacuum Vacuum

Cover preform with vacuum film

Semi finished cuts Preform

Preform placement in matched rigid mold

Cured component Resin

2. Resin transfer molding - RTM

Inject resin; impregnation and curing

Semi finished cuts Preform

Preform placement in matched rigid mold; apply vacuum

Cured component

3. Vacuum assisted resin transfer molding - VARTM _Resin

Inject resin; impregnation and curing Vacuum Vacuum Vacuum Vacuum

RTM – Process Technology

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RTM – Process Technology

HP- RTM Process

Resin

Semi finished cuts Preform Cured component Inject resin at high

pressure (60-100 bar); impregnation Apply high compression force Complete impregnation and curing Preform placement in matched rigid mold; apply vacuum

Vacuum Vacuum Vacuum

High pressure injection RTM – HP-RTM

Advantages of High Pressure RTM:

Rapid mold filling

Improved impregnation quality

Accelerated resin reactivity system can be applied – short cycle time Significant reduction of air entrapments and voids

Excellent surface properties

Low tolerance in thickness and 3D shape High process stability and repeatability

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01 | 2010 – Seite 10 Automobile Trucks Train Boat/ Shipbuilding Aerospace Agricultural equipment

Potential for lightweight design

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Bild Quelle Internet

Target Light weight design

Structural Body parts

Side Frame Roof Underbody structure Audi R8 Spyder BMW M6 BMW Project I CityCar Bumper

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01 | 2010 – Seite 12

Cooperation Dieffenbacher – Krauss Maffei

RTM Preforming

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Cooperation KraussMaffei - Dieffenbacher

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01 | 2010 – Seite 14 Tool Cleaning Tank /Storage System Line Control Line Automating Press process Pre-forming Metering technology Mixing head Post Treatment Tooling

Bild Quelle Internet

Cooperation KraussMaffei - Dieffenbacher

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Cooperation Dieffenbacher – Krauss Maffei

RTM Preforming

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01 | 2010 – Seite 16

RTM – Process

Process Chain Draping and Preforming Handling of Fabrics Layup and Fixing Contur Cutting _Unrolling of Fabrics Net-Shaping of Preform Handling into

Press Mold Closure of Press Mold Resin Injection Unloading and Finishing Mold Cleaning Finished RTM Part Preform Fiber Fabrics

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Draping and Preforming Layup and Fixing Handling of Fabrics Contur Cutting _Unrolling of Fabrics Net-Shaping of Preform Handling into

Press Mold Closure of Press Mold Resin Injection Unloading and Finishing Mold Cleaning Preform Fiber Fabrics

RTM – Process

Process Chain

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01 | 2010 – Seite 18 90 mm 40 mm 1.400 mm 1. 60 0 m m Materials: Woven fabrics Fiber material Binder material Size: Dimension 1.400 x 1.600 mm Height 100 mm Thickness 2.5 mm Layup: Number of layers Type of fabrics Local reinforcement Inserts

RTM – Preforming

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RTM – Process

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01 | 2010 – Seite 20

Cutting Mechanical

CNC stamping

cutting blade Ultrasonic

Other / Energy

Laser Plasma Roll cutting

circular blade

Cutting device and cutting knife depends on used material

RTM – Preforming

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Mechanical

CNC stamping

cutting blade Ultrasonic

Roll cutting

circular blade

RTM – Preforming

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01 | 2010 – Seite 22

Gripper

non-positive-locking _{adhesive-locking} positive-locking

vacuum electrostatic molecular mechanical

vacuum gripper Bernoulli electr. adhesion adhesion film freeze gripper needle gripper grate gripper

RTM – Preforming

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Fixing of Fabrics

chemical thermal mechanical

bonding welding stitching needling knitting

powder binder fleece binder hot glue liquid binder thermoplastic fiber thermoplastic resin classical stitching one-sided stitiching

RTM – Preforming

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01 | 2010 – Seite 24 2D Shape 3D Shape 1 lay-up n lay-up Robot Gripper CF

Cutting table / lamination table Preforming tool

Single fabrics Fixed Multi layer fabrics

RTM – Preforming

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RTM Dosing Systems

RTM Tool Design RTM Press Concept RTM Machining

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01 | 2010 – Seite 26

RTM Dosing Systems

Pump Dosing Maschine

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Hydraulic System

_{Strong system to realize}

multi point injection Special Working Tanksystem

_{Vacuum system}

_{Refilling by Vacuum}

RTM Dosing Systems

New Metering concept from 20g/sec to 200g/sec

Special Working Tanksystem

_{Free selectable part counter}

_{Variable shift classification}

_{Trend diagram}

_{Profile data recording}

_{Maintenance plan}

_{Failure protocol}

_{Administration of up to 512}

different foaming programs

Release agent Dosing

_{Direct feeding to mixing head}

_{increase de-molding} properties Heating chamber

_{Preheating of 200l Barrel}

_{Constant temperature} control up to 120°C

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01 | 2010 – Seite 28

Outstanding Lifetime

_{due to intelligent}

composition of special materials and surface treatments

Impingement Mixing

_{Self cleaning system}

_{No static mixer necessary}

_{up to 120°C working range}

_{suitable for high speed}

system

RTM Mixinghead

High Pressure Mixingsystem

Release agent dosing direct at Mixing head

_{amount adjustable}

_{Controlled by PUC 07}

_{no contamination of}

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RTM Dosing Systems

RTM Tool Design

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01 | 2010 – Seite 30

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Sealing Concept

→ Special sealing concepts for low viscose RTM systems

Vaccum System

→Patented Vacuum system to ensure 100% resin filling

Multi Mixing head injection

→Tool can be prepared for x numbers of mixing heads (pressure reduce filling process) Integrated Pressure measurement → to ensure 100% filling of cavity → minimize rejection

RTM Tool Design

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RTM Press Concept

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01 | 2010 – Seite 32

Fully automated press concept for large

production volume. Key features:

_{High Pressure}

process for fast reacting resins and high surface quality

_{High precision and}

high speed leveling system

_{Full automation and}

process control

RTM – Press Concept

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Hydraulic Press System: COMPRESS PLUS Energy efficient ram closing

Short stroke cylinders with mechanical locking system

RTM – Press Concept

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01 | 2010 – Seite 34

High speed

High precision

leveling system

flow control and

process control

high accuracy in

part thickness

RTM – Press Concept

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Fully automated system including:

Preform handling into the mold

Mold transfer into the press

Resin injection

Unloading of finished part

Transfer into rack Mold cleaning

Complete process control

RTM – Press Concept

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01 | 2010 – Seite 36

RTM Cooperation Dieffenbacher – Krauss Maffei RTM Preforming

RTM Press Concept

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Knife Cutting

Machining Center Interior

3D-Simulation

Offline-Programming Handling

RTM – Machining

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01 | 2010 – Seite 38

Machine with horizontal turning wall and 2 robots

Technic-Rack on back frame

Horizontal-turning wall

→Working range BxH 3000x1600 mm

Tool changing system

Mobile Robot-cell

Modern waste management

Complete open operators area

RTM – Machining

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07 | 2010