Automated layup of sheet prepreg

Transcription

1 Carwyn Ward, Kevin Potter

2 About me Researchers Centre for Doctoral Training (CDT), Industrial Doctorate Centre (IDC), CIMCOMP Nottingham, Bristol, Cranfield, Manchester

3 High quality manufacturing 3 Hand layup Adaptable Complex shapes Slow Variable AFP/ATL Repeatable Fast Simple shapes High fibre alignment Defect free Ply-by-Ply layup

4 High quality manufacturing 4 Hand layup Adaptable Complex shapes Slow Variable? New process Complex shapes and Fast AFP/ATL Repeatable Fast Simple shapes

5 Early attempts 5 Only simple, single curvature shapes

6 High quality manufacturing 6 Hand layup Flexible Complex shapes Slow Variable? New process Complex shapes and Fast AFP/ATL Repeatable Fast Simple shapes

7 Layup is difficult: 7 Video removed to reduce file size: Search ACCIS automation on youtube or go to for video

8 Understanding Hand lamination 8 A selection of layup trials were conducted 19 Parts 6 Laminators All Analysed for Techniques, Times, and Defects.

9 Understanding Hand lamination 9 7 basic techniques Multiple feedback loops Lots of feedback Combined = Complex process Very difficult to automate

10 Simplify the process: Preshearing 10 Start with kinematic model Apply shear deformation prior to tool contact. Ply already fits into tool and deforms easily Reduced Layup time and effort.

11 10 cm Preshearing: The evolution of layup Model the required deformation. 5. Consolidation by hand: 2. Translate deformation to a flat ply. 3. Apply rectangular indicator field (RIF) to prepreg. 4. Apply deformation to ply away from the tool.

12 Preshearing: The evolution of layup. 12 The rectangular indicator field (RIF) The material should be stretched ( ) until the rectangles become square. 1. Location 2. Direction 3. Angle

13 10 cm Preshearing: The evolution of layup Model the required deformation. 5. Consolidation by hand: 2. Translate deformation to a flat ply. 3. Apply rectangular indicator field (RIF) to prepreg. 4. Apply deformation to ply separately from the tool.

14 A two stage Process 14 Up to 40% time savings Up to 70% reduction in interactions during layup One complex process Two simple process Automation became a possibility

15 A two stage automated Process 15 Stage 1: Preshearing Stage 2: Layup Target mould - 400mm 600mm

16 Stage 1: Automated preshearing 16 Preshearing is achieved using a press.

17 Stage 2: Automated layup 17

18 Multiple end effectors 18 AFP Single integral End effector New process Multiple specialised versions

19 Multiple end effectors 19 Cylinder: Flat and convex surfaces.

20 Multiple end effectors 20 Profiled': Moderate internal radii.

21 Stage 2: Automated layup 21 Reinforced wedge: Tight radii corners.

22 Stage 2: Automated layup 22 Video removed to reduce file size: Search ACCIS automation on youtube or go to for video

23 The finished product 23

24 Automated vs Hand layup 24 Robot: 7m30s Hand: 7m

25 Fan Blade layup: 25 Video removed to reduce file size: Search ACCIS automation on youtube or go to for video

26 Flexibility: New end effectors 26 Too tight for existing rollers?: Make a new one. Metal core

27 Flexibility: New end effectors 27

28 Key Achievements 28 Documented understanding of the hand layup process Significant reduction in the time for hand layup First automated layup of prepreg over a complex mould Flexible process

29 Further work 29 New shapes New improved preshearing techniques Joining the two stages: Pick and place

30 Sponsors