Cevotec通過(guò)多材料鋪設(shè)擴(kuò)大了夾層結(jié)構(gòu)的應(yīng)用范圍
日期：2018-08-23
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光纖貼片放置（FPP）已成為復(fù)雜纖維復(fù)合材料部件自動(dòng)化生產(chǎn)的選技術(shù)。具有適當(dāng)尺寸的貼片的部件的增材制造尤其用于航空航天和汽車(chē)工業(yè)，醫(yī)療設(shè)備和運(yùn)動(dòng)設(shè)備。通過(guò)與的航空航天工業(yè)零部件制造商的密切合作，Cevotec根據(jù)行業(yè)要求進(jìn)一步開(kāi)發(fā)整個(gè)貼片貼裝工藝。
Cevotec的FPP專(zhuān)家對(duì)復(fù)雜的夾層部件及其復(fù)雜的材料混合物特別感興趣，如粘合膜，玻璃纖維和碳纖維層。這些不同的材料用于改善碳纖維材料與常用的鋁蜂窩夾層芯的粘合性和可加工性。
“我們目前正在開(kāi)發(fā)的SAMBA Multi生產(chǎn)系統(tǒng)能夠在一個(gè)系統(tǒng)中自動(dòng)鋪設(shè)這種特殊的多材料混合物，”Cevotec席技術(shù)官Felix Michl表示。
除了玻璃纖維羊毛，金屬結(jié)構(gòu)和木芯，蜂窩芯，固體泡沫和其他材料已經(jīng)享受了負(fù)載調(diào)整的纖維補(bǔ)片增強(qiáng)。根據(jù)工藝要求，可以在線生產(chǎn)或與生產(chǎn)線并行完成，以?xún)?yōu)化循環(huán)時(shí)間。
SAMBA Multi具有用于不同材料的平行進(jìn)料裝置，這些裝置在一個(gè)生產(chǎn)系統(tǒng)中加工并精確放置在三明治芯或預(yù)成型工具上。通過(guò)將FPP單元安裝在線性軸上，該概念還使得能夠在航空航天應(yīng)用中生產(chǎn)特別長(zhǎng)且寬的部件。根據(jù)特定的元件尺寸，我們還根據(jù)DIN-A5和DIN-A4尺寸調(diào)整貼片夾具，以滿(mǎn)足普通飛機(jī)部件的要求。集成的夾持站可在此過(guò)程中更換夾具。
“復(fù)雜夾層部件的自動(dòng)化多層材料鋪設(shè)對(duì)加工時(shí)間和生產(chǎn)量產(chǎn)生了極為積極的影響，”Cevotec董事總經(jīng)理Thorsten Groene解釋道：“壓力和熱量受控的纖維沉積能夠避免中間壓實(shí)因此，Groene繼續(xù)說(shuō)道，F(xiàn)PP可持續(xù)地降低許多應(yīng)用中的經(jīng)常性生產(chǎn)成本。當(dāng)然，材料節(jié)省20％ - 50％起著重要作用，但FPP自動(dòng)化通常可以進(jìn)一步優(yōu)化整個(gè)過(guò)程。“
SAMBA Multi的另一個(gè)優(yōu)點(diǎn)是生產(chǎn)過(guò)程的高可擴(kuò)展性。“同一個(gè)過(guò)程每年都會(huì)產(chǎn)生幾百到幾千個(gè)單位，”Michl解釋道。例如，這些是即將到來(lái)的“飛行汽車(chē)”行業(yè)的預(yù)期情景。“由于快速更換系統(tǒng)和較短的安裝時(shí)間，系統(tǒng)上的產(chǎn)品更換沒(méi)有問(wèn)題且經(jīng)濟(jì)上合理：在加速期間，F(xiàn)PP系統(tǒng)的容量可用于多個(gè)組件。隨著數(shù)量的增加，機(jī)器公園得到擴(kuò)展，系統(tǒng)變得更加專(zhuān)注。優(yōu)勢(shì)：流程保持不變 - 無(wú)需新產(chǎn)品開(kāi)發(fā)，也無(wú)需重新認(rèn)證零件。“
“由于FPP和AFP工藝都用于航空航天工業(yè)，F(xiàn)PP和AFP的層壓板規(guī)劃是否可以在我們的CAE軟件ARTIST STUDIO中結(jié)合使用的問(wèn)題，自然而然地在開(kāi)發(fā)過(guò)程中出現(xiàn)。明確的答案：是的，它可以是合并后，“Cevotec執(zhí)行副總裁Neven Majic博士補(bǔ)充道。
因此，F(xiàn)PP專(zhuān)家目前正在通過(guò)AFP工藝中使用的無(wú)端纖維帶的層壓設(shè)計(jì)相關(guān)功能擴(kuò)展ARTIST STUDIO。新模塊TAPE ARTIST與ARTIST STUDIO無(wú)縫集成，還將使用MOTION ARTIST進(jìn)行機(jī)器數(shù)據(jù)生成和過(guò)程模擬。TAPE ARTIST還可以與PATCH ARTIST結(jié)合使用到一個(gè)聯(lián)合模塊，使工程師能夠設(shè)計(jì)基于AFP和FPP技術(shù)的集成層壓板。
原文如下：
Cevotec expands application range by multi-material layup for sandwich structures
Fiber Patch Placement (FPP) has become the preferred technology for the automated production of complex fiber composite components. The additive manufacturing of components with suitably-sized patches is used especially in the aerospace and automotive industries, for medical devices and sports equipment. In close cooperation with leading manufacturers of components for the aerospace industry, Cevotec further develops the entire patch placement process according to the requirements of the industry.
Cevotec’s FPP specialists are particularly interested in complex sandwich components with their sophisticated material mix, such as adhesive films, glass fiber and carbon fiber layers. These different materials are used to improve the adhesion and processability of carbon fiber material with the often-used aluminum honeycomb sandwich cores.
"The SAMBA Multi production systems, which we are currently developing, enables the automated lay-up of this special multi-material mix in one single system," reports Felix Michl, Cevotec's CTO.
In addition to glass fiber fleeces, metal structures and wood cores, also honeycomb cores, solid foams and additional materials have already enjoyed load-adjusted fiber patch reinforcements. Depending on process requirements, this can be done in-line or parallel to line production to optimize cycle times.
SAMBA Multi has parallel feeding units for different materials that are processed in one production system and placed precisely on 3D sandwich cores or preforming tools. By mounting the FPP unit on a linear axis, the concept also enables the production of particularly long and wide components in aerospace applications. Adapted to specific component sizes, we also scaled the patch grippers to DIN-A5 and DIN-A4 size to meet the requirements of common aircraft components. An integrated gripper station enables the exchange of grippers during the process.
"The automated multi-material lay-up of complex sandwich components has an extremely positive effect on process times and thus the production volume," explains Thorsten Groene, Managing Director of Cevotec: "The fiber deposition with controlled pressure and heat enables skipping intermediate compactions and thus reduces process times significantly.” In addition, Groene continues, FPP sustainably reduces recurring production costs in many applications. "Material savings of 20% - 50% play a major role, of course, but automation with FPP often enables further optimization of the overall process.”
Another advantage of SAMBA Multi is the high scalability of the production process. "One and the same process works both for a few hundred and several thousand units per year," explains Michl. These are expected scenarios in the up-and-coming “flying car” industry, for example. " Thanks to the quick-change system and short set-up times, a product change on the system is no problem and economically reasonable: During ramp-up, an FPP system’s capacity can be used for several components. With increasing quantities, the machine park is expanded and the systems become more dedicated. The advantage: the process remains the same – no new product development and no re-qualification of parts are necessary."
"Since both FPP and AFP processes are used in the aerospace industry, the question whether laminate planning for FPP and AFP can be combined in our CAE software ARTIST STUDIO, naturally arose in the course of development. The clear answer: yes, it can be combined," adds Dr. Neven Majic, EVP at Cevotec.
Therefore, the FPP specialists are currently extending ARTIST STUDIO by the relevant features for laminate design with endless fiber tapes as used in AFP processes. Seamlessly integrated into ARTIST STUDIO, the new module TAPE ARTIST will also use MOTION ARTIST for machine data generation and process simulation. TAPE ARTIST can also be combined with PATCH ARTIST to one joint module, enabling engineers to design integrated laminates based on AFP and FPP technology.
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