JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 29

on Automatica

Process

thermoplastic matrix materials, especially in unidirectional fibre reinforced parts. This effect may even exist when processing thermoplastic FRP by compression moulding, even though a closed mould and a symmetric temperature profile within the parts are associated with this process. Both these features are lacking in the laser-assisted tape laying process. However, the Institute successfully handled the challenge to produce even, non-deformed plates in multiple ways. An inadequately adjusted lay-up of thermoplastic prepregs by tape laying results in component deflections (Fig. 2). These deflections can be subdivided into lateral and longitudinal deflection, as well as twisting. Lateral deflection can be easily explained by the deflection model of Stitz [STI73] and has been compensated by accurate temperature control during the process. Among others, the twisting effect is caused by varying degrees of compaction in the laid-up prepregs. Twisting was eliminated by precise force control. Longitudinal deflection is caused by fibre corrugations within the prepreg (Fig. 3). The amount of corrugation is a function of the applied force, force distribution and induced

temperature. This effect can be avoided by the correct adjustment of these parameters. A thorough understanding of the process is important in the laser-assisted tape laying of thermoplastic prepregs. Capitalizing on the gained knowledge, the Institute developed precise temperature and force control systems. Since the use of a stiff roller has certain drawbacks in the production of two- and three-dimensional parts, the Fraunhofer IPT developed novel consolidation systems for gentle material lay-up and stable production of complex parts. The process investigations were performed on flat and windable parts (Fig. 4).

Fig. 4: Produced and investigated components (down); The compact tape laying unit at Fraunhofer IPT (up)

Outlook
Based on the acquired process understanding and the ambition to perform the automated production of complex, high-performance composite parts, the Institute developed a modular fibre placement unit with integrated fibre coupling to a diode laser source. The fibre placement system was developed under the 3D-Thermolay research project funded by the German Federal Ministry of Economy and Technology. The 3D Thermolay system is specially designed to lay up complex, three-dimensional structural components (Fig. 5). The Formula 1 monocoque is a good example for explaining the benefits of the novel system. The good properties of thermoplastic FRPs, such as high impact strength and low density, can be used to produce complex, safety-relevant structural components with reduced weight. Due to the fusibility of thermoplastic FRPs, functional elements can be joined to the main structure without additional adhesive materials. The high energy efficiency of the process allows

Fig. 2: Deflection effects on thermoplastic FRPs

Fig. 3: Surface effects on thermoplastic prepregs laid up with a plain stiff roller

No57 May 2010 / jec composites magazine

29



JEC COMPOSITES MAGAZINE - Issue #57 - May 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #57 - May 2010

Cover
Editorial
Market Place
Advertisers
Index
Contents
NEWS WORLDWIDE
- Companies
- Agenda of events
- Equipment
BUSINESS
- Market survey
- Trends
- Niche Market
- Human Capital
FEATURE - AUTOMATION
- 3D X-ray
- Process
- CNC
- Control
- FCS
- Filament winding
- Robotics
USERS' PLATFORM
- Composites in the world
- Successful Partners
- Application
KNOW-HOW
- Preform Control
- Thermoplastics
- Mould
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Editorial
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Market Place
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Index
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Companies
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Equipment
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 11
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 12
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 14
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Market survey
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Trends
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 19
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 22
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Niche Market
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Human Capital
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - FEATURE - AUTOMATION
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - 3D X-ray
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Process
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 30
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - CNC
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Control
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 34
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - FCS
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Filament winding
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Robotics
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Successful Partners
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 43
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Application
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 45
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 46
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 47
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 48
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Preform Control
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 55
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Mould
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 57
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 58
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 60
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