The MAPICC 3D project and concept answers to the requirements of call NMPFP7- 2010-3.4-1: Manufacturing systems for 3D shaped, multilayered products based on flexible materials. Therefore MAPICC 3D is focused on the development of industrial processes for automated on line production of up graded thermoplastic composites based on 3D textile structures that are manufactured with innovative textile and composites technologies. Fully automated and highly adaptable manufacturing processes need to ensure a highly reliable production rate at low cost, accordingly to the complexity of textile structure. The expected advancement is a reduction of preform cost of about 38 % in comparison with actual status and a productivity improvement of about 14 % time to market. The development of industrial products will be assisted by innovative modelling. Therefore it is the aim to predict the behaviour of the manufactured products and to identify the most suitable configuration corresponding to the requirement of end users. The technology chain covers the yarn development, processing into 3D textile structure by novel technologies, consolidation of the composites and life-time monitoring as well as recycling. The fields of application for the composites are panels and stiffeners for transportation systems (automotive and railways applications), building and energy applications. Composite materials are mainly made by lamination, which is a time consuming technique. Large scale manufacturing is done e.g. by compression moulding of prepregs, but this is sometimes limited to short glass-fibre reinforced thermoplastics (GMT). Both techniques will give good in-plane properties of the composite, but not out-of-plane (cross-section) due to interlaminate shear and delaminating. To promote a technological breakthrough, one of the main tasks of the project will be the development and setting up of technologies at a pilot scale able to realize textile structures for rectilinear or curved stiffener (ENSAIT) and panels (ITM) with 3D evolution of fibres on the basis of weaving (ENSAIT) and weft knitting technology (ITM). Such structures are expected to be very efficient for high energy absorption while using as crash-related components. The simulation tools to be developed in the frame of this project will be based upon an existing finite element code of the ESI's PAM Solutions. This will give access to the physical detailed description of the location, orientation and trajectories of the fibres. The simulation tool will also enable testing of new process parameters controlling kinematics of developed technology. The full process will be simulated on small components. Mechanical properties will be extracted from the obtained 3D geometry using virtual mechanical testing on samples. Thermo-mechanical distortion effects will be modelled. Also models proposed by ARMINES regarding consolidation and fusion bonding of thermoplastics will be implemented. The consortium will study the relationship between yarns, processing conditions, microstructures of the 3D preform and final properties of composite parts The consortium involves industrial stakeholders from machine tooling and automation, modelling (Steiger, Reden, ESI group, ESI GmbH), processing of flexible materials (Dylco, Tencate), yarn and textiles manufacturing (Ferlam), composites manufacturing (Tencate, Coexpair, Mecacorp, Finieris) and also end users main focus on transport applications (automotive: Volvo Trucks, railway: Alstom, aeronautic: CoExpair). The industrial partners within MAPICC 3D are the majority and insure the leadership of the proposal. The consortium as such covers the entire process chain of a composite part.


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    Title :

    One-shot Manufacturing on large scale of 3D up graded panels and stiffeners for lightweight thermoplastic textile composite structures (MAPICC 3D, 263159-1)


    Contributors:


    Publication date :

    2012


    Size :

    3 Seiten, 5 Bilder, 1 Quelle



    Type of media :

    Conference paper


    Type of material :

    Storage medium


    Language :

    English




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