Transcript NOUS Composites Research Hub « [Di tutti gli esseri...] il più veloce è l'intelletto (νοῦς), perché corre ovunque.

NOUS
Composites Research Hub
« [Di tutti gli esseri...] il più veloce
è l'intelletto (νοῦς), perché corre
ovunque. » Diogene Laerzio (I,35)
Overview on our Solutions in Composites Manufacturing
 Background and Mission
Overview on our Solutions in Composites Manufacturing
 Equipment and Engineering SW
 Market & Partners
 Aerospace Industry & Composites
 Thermoplastic vs. Thermoset Composites
 Technology - Targeted Innovation
 A Look to the Future
2014 NOUS Proprietary
Background and Mission
Overview on our Solutions in Composites Manufacturing
NOUS Composites Research Hub was born 2012 from an innovation driven joint
venture between Novotech s.r.l. and Compositi Avanzati s.r.l. with the aim to improve
existing technologies and develop new solutions in design and manufacturing of
composite materials.
Thanks to a continuous exchange of engineering expertise and manufacturing
capabilities a Team composed by valued researchers coming from Universities and
Research Centres aspires to create a Centre of Excellence in the research and design
of composites in Southern Europe.
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Equipment and Engineering SW
Overview on our Solutions in Composites Manufacturing
Composites Manufacturing Process with:
 ABB
IRB-6640/205/2.75
standard robot 8-fibre placement
head, developed by Coriolis
Composites
s.a.s.
(Quéven,
France), mounted on a linear axis
with a working length of 3m. The
heating of the material can be
performed by a 3kW laser (LDM
3000-100) or Infra-Red lamp;
 Hypaject MKIII Injection
Thermostatted System up to
10bar Injection Pressure for
RTM;
 2 Freezers for Resin Prepreg Storage 1.0mx3.0m and 1.0mx1.8m;
 Redundant Vacuum Infusion Systems;
 Extractor Bench for Sanding Dust (Composites Tooling);
 Bench for Cutting composites.
Product Design Simulation Process with:
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 Hot Press for RTM
and CM with plates of
1.2mx1.8m, 400°C
Insulated Plates;
 Composite Curing Oven
400°+/-2°C Uniformity
Temperature
of
1.0mx1.0mx1.2m
with
Vacuum Line;
Background and Mission - NOVOTECH s.r.l.
Overview on our Solutions in Composites Manufacturing
Novotech s.r.l. is an engineering innovation partner for companies in the aerospace
field and advanced technology industries.
The Company has been founded in 1983 as spinoff consulting engineering company
from the Department of Aerospace Engineering of the University of Naples
“Federico II”.
It still maintains roots and backbone with scientific institutions, as Universities and
Research Centres, keeping a strong link and continuing relationship, especially, but
not exclusively, in the aerospace field.
Continual Novotech s.r.l. research leads to advanced, more robust solutions for even
the most complex engineering problems.
As a proof of such spirit, recently the Company decided to invest on innovative
techniques for manufacturing of composites equipping itself of an Automated Fiber
Placement machine.
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Background and Mission - NOVOTECH s.r.l.
Overview on our Solutions in Composites Manufacturing
Since 1983 Novotech s.r.l. is aimed to
 Provide technical-scientific support (Aeroelastic and Acoustics Certification) and advanced
testing support (Ground Vibration Tests, Noise Tests, Landing Gear Drop Tests) to SMEs as
Partenavia, Generalavia, Sky Arrow, TECNAM, OMA SUD, Vulcanair and others.
 Develop technical-scientific partnerships on specific technological tasks with big aerospace
industries:
Aeritalia/Alenia Aermacchi: internal noise (ATR), advanced F.E.A. on metal-CFRP
structures, European Research Programs;
Alfa Romeo Avio/Fiat Avio: advanced F.E.A. on turbine components;
AgustaWestland: advanced F.E.A. on metal-CFRP structures;
Magnaghi Aeronautica: Crashworthiness of tanks, advanced F.E.A. on composite
structures (Bombardier);
DEMA: Aeroelastic calculations for gust loads on Bombardier G-7000.
 Work for the cross-sector technology transfer (Aerospace, Automotive, Railway, Naval
and Civil Engineering) for some specific issues within its main competences.
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Background and Mission - NOVOTECH s.r.l.
Overview on our Solutions in Composites Manufacturing
Novotech s.r.l. has always been involved in research projects in partnership with
Universities, Research Centers and companies concerning design, testing and
manufacturing of aeronautical structures as MESEMA (Magnetoelastic Energy Systems
for Even More Electric Aircraft) FP6-AST3-CT-2003-502915, SARISTU (Smart Intelligent
Aircraft Structures) FP7-AAT-2011-RTD-1, etc.
In addition to these ongoing activities, Novotech s.r.l. has attended directly in the
following research projects:
 ASAM: Advanced Simulation of Aircraft Mechanisms - EU Project (Call identifier: SP1JTI-CS-2013-01-GRA-02-023/Topic number: JTI-CS-2013-1-GRA-02-023);
 LAMITECH: Innovative Testing Methods for Automatic Layering of Hybrid Composite
Materials (Program Contract Apulia Region - Alenia Aermacchi S.p.A.);
 PROALATECH: Structural Characterization and Repair Solutions Analysis of Innovative
CFRP Empennages (Program Contract Apulia Region - Alenia Aermacchi S.p.A.);
 FACE : Friendly Aircraft Cabin Environment - EU Project (G4RD-CT2002-00764).
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Background and Mission - Compositi Avanzati s.r.l.
Overview on our Solutions in Composites Manufacturing
Compositi Avanzati s.r.l. is a manufacturing firm which deals in design, development and
production of composite components, either for structural or non-structural applications,
through the Resin Transfer Moulding (RTM) process and other closed mould technologies.
The main company business is the production of Carbon Fibre Reinforced Polymers (CFRP) for
the aerospace industry either with thermosetting or thermoplastic matrices. Side production
sectors are the naval, railway and automotive industries.
The use of the closed mould technologies permits the realisation of composite elements with
complex shape, tight dimensional tolerance, embedded inserts, high quality finished surfaces,
excellent reproducibility on a part to part basis and environmental compliance.
Besides
manufacturing
and
quality
control,
Compositi
Avanzati
s.r.l.
accomplishes the design of the elements to be realised by RTM or other
closed
mould
processes,
as
well
as
a
significant
R&D
activity
to
continuously improve the production process.
Recently, Compositi Avanzati s.r.l. has provided to University of Naples “Federico II” a set of
composite stiffened panels manufactured with RTM technique for an International Research
and Technology Project concerning Aircraft Expedient Repairs.
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Markets & Partners
Overview on our Solutions in Composites Manufacturing
Applications demanding low weight, high stiffness-to-weight and strength-to-weight
as well as high productivity rates are the key targets for us.
Markets
Partners
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Aerospace Industry & Composites
trend
STATUS AND TARGETS FOR COST
OF COMPOSITE STRUCTURES
Source: Composites Forecasts & Consulting
Overview on our Solutions in Composites Manufacturing
Today, metallic structures are being replaced by composites for vehicle weight reduction and
resultant fuel savings.
The costs of composite components have to be
reduced down to the level known from conventional
metal structures. This can only be achieved through
changes in materials and manufacturing processes.
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Thermoplastic vs. Thermoset Composites
Thermoplastics
 are typically 4-times tougher than comparable
thermosets, which results in more impact resistance and
damage tolerance.
 are relatively insensitive to aircraft fluids and chemical
attack, and with one exception (PEIs), insensitive to
moisture.
 offer substantial reductions in flammability, smoke and
toxicity performance.
 also exhibit a near-infinite shelf life at room
temperature.
The potential value that thermoplastics bring to the
aerospace market becomes more apparent when
neat resin performance characteristics are
compared with raw material costs.
Source: Composites Forecasts & Consulting LLC
Overview on our Solutions in Composites Manufacturing
Many TP polymers have raw material prices
comparable to, and the high tensile strength of,
common thermosetting resins.
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High-Performance Composite - May 2011
Thermoplastic vs. Thermoset Composites
Overview on our Solutions in Composites Manufacturing
PEEK, PPS, PEI and PC show many favorable characteristics for application in both aerospace
structures and interior components:
 The cost of finished TPs components can be roughly 20 to 40% lower than competing TS
due to reduced handling, processing and assembly costs.
 TPs offer the option to fuse or weld molded subcomponents, which can reduce assembly
weight and stress concentrations by eliminating fasteners and adhesives.
For high-temperature applications, PPS,
PEI and PEEK polymers also offer excellent
thermal stability - beyond the capabilities
of
high-temperature
epoxy
TS
(~180°C/~350°F).
At elevated temperatures, PEEK and PPS
TPs, priced between $4 and $72/lb ($9 and
$160/kg) can offer potentially substantial
savings compared to BMI and PI TS, priced
between $42 and $400/lb ($92 and
$880/kg).
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Technology - Targeted Innovation
Overview on our Solutions in Composites Manufacturing
00
Compression
Moulding Process
Resin Transfer
Moulding Process
Injection
Moulding Process
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Automated Fiber
Placement Process
Design & Manufacturing of Composite Layups by
Compression Moulding Technique
Overview on our Solutions in Composites Manufacturing
Compression Moulding is a closed mould process in which a moulding charge is squeezed
into a preheated mould taking a shape of the mould cavity and cured by the heat and
pressure applied to the material.
The process involves the following steps:
 A pre-weighed measure of a polymer assorted with slices reinforcing fibers, hardening
agent, anti-adhesive agent and pigment is positioned into the lower half of the mould.
 The mould cavity is filled by forcing and pressing on the charge and thereby the upperhalf of the mould shift downwards.
 With the help of the ejector pin the mould is opened and the part is removed.
This method is capable of reproducing fiber-reinforced plastic parts in significant volumes,
with high quality finish surfaces, repeatability and speed.
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Design & Manufacturing of Composite Layups by
Resin Transfer Moulding Technique
Overview on our Solutions in Composites Manufacturing
This method offers high precision moulded parts and enables integrated solutions offering high
quality and repeatability beyond a reduction of weight, costs and assembly time.
Exploded view of
components used
in RTM process
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View as built of Composite Stiffened Panels
(TS) samples manufactured by RTM process
for an International R&T Project with
University of Naples “Federico II”
Design & Manufacturing of Composite Layups by
Resin Transfer Moulding Technique
Overview on our Solutions in Composites Manufacturing
TEST TRIAL:
DESIGN AND DEVELOPMENT
OF A RIB MANUFACTURED
BY RTM PROCESS
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Design & Manufacturing of Composite Layups by
Injection Moulding Technique
Overview on our Solutions in Composites Manufacturing
Injection Moulding is a process in which
molten polymer is forced under high
pressure into a mold cavity through an
opening (sprue).
Injection Moulding is highly productive
method providing high accuracy and
control of shape of the manufactured
parts. The method is profitable in mass
production of large number of identical
parts.
Thermoplastics commonly used
Injection Molding are PP, PC, ABS, N6.
in
ONGOING RESEARCH & DEVELOPMENT PROJECT :
DEVELOPMENT OF A THERMOPLASTIC
COMPOSITE SEAT ARMREST
Injection speeds are typically 1 to 5
seconds, and as many as 2,000 small
parts can be produced per hour in some
multiple-cavity molds.
Finite Element Analysis
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Design & Manufacturing of Composite Layups by
Automated Fiber Placement Technique
Overview on our Solutions in Composites Manufacturing
From this year NOUS is involved in research projects dealing with the investigation and
characterization of innovative configurations and processing of CFRP multi-layer materials
to manufacture with automated technology (LAMITECH Research: Program Contract Apulia
Region - Alenia Aermacchi S.p.A.).
.
With an ABB IRB-6640/205Kg/2.75m
standard robot having an 8-fibre placement
head, mounted on a linear axis with a
working length of 3m, we are able to
process TS, TP and DF composite materials.
TEST TRIAL: FLAT COMPOSITE PANEL WITH A RAMP
The heating of the material can be
performed by a 3kW laser or IR device.
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DF
25’ for 16 plies
(750 mm x 750 mm)
TP
50’ for 16 plies
(1500 mm x1500 mm)
Design & Manufacturing of Composite Layups by
Automated Fiber Placement Technique
Overview on our Solutions in Composites Manufacturing
COMPARISON OF DIFFERENT MANUFACTURING TECHNOLOGIES
FOR CFRP FUSELAGE PANELS MULTI-LAYER MATERIALS
DOUBLE CURVATURE COMPOSITE
PANEL WITH RAMP
Test
trial
CONCEPT, DESIGN AND FEASIBILITY STUDY
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MANUFACTURING
Design & AFP Manufacturing of Composite Parts
Overview on our Solutions in Composites Manufacturing
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Activities in Development
Overview on our Solutions in Composites Manufacturing
 Production of a standard sandwich-structured
composite with AFP procedure
 OOA Acceptance with AFP machine
 Productivity Test - Lamination of flat panels
 Productivity Test – Lamination of stringers for fuselage
 Productivity Test – Lamination of windows frame
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Activities in Development
Overview on our Solutions in Composites Manufacturing
 Rotating Positionner
Vertical spindle axis interpolated with robot axis.
► Motorized head-stock.
► Handling capacity: 3 000 kg.
► Max tool diameter: 3 meters.
► Gear box reduction that has to be defined before
being ordered:
► Max tool inertia 6000 m²kg, max speed 8 rpm and
max acceleration 45°/s².
► Or max tool inertia 1500 kgm², max speed 16 rpm
and max acceleration 90°/s².
► This payload on the positioner is only an
approximate value regarding the final usage. For
each mold, the load, inertia and torques have to be
checked separately
► Repeatability: ±0.05 mm at 500 mm radius.
► The positioner is fixed to the ground nearby the
linear axis.
► Customer color RAL.
► Foundations are not included in this option.
► Fixation by welding the linear unit to HEB beam
integrated into the ground, into concrete with
minimal characteristic C 20/25 thickness 220 mm.
Customer foundation studies must be
communicated to Coriolis in advance.
► HMI and software functionality, installation.
► Energy, air and vacuum supply system for
Customer are available on request.
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A Look to the Future
Overview on our Solutions in Composites Manufacturing
 Out of autoclave solutions
 Multifunctional composites
 Increase capabilities in manufacturing even more complex shapes
 Analytical tools to support manufacturing processes
 Consolidation and reduction in parts required to produce assemblies
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Thank you
for your attention
If You Want To Go Fast, Go Alone.
If You Want To Go Far, Go Together.
2014 NOUS Proprietary