JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 37

- net-shape design with
multi-thickness and multiorientation patches;
- very short cycle times,
robust high-volume capacity and competitive cost.
Cetim's industrial partners
(Pinette PEI, Loiretech and
Compose Tooling) built the
pilot line and now propose
a modular, scalable and
flexible line based on proven
technology. For example, the
cutting unit can be adapted
to use semi-products available on the market rather
than in-house pultruded
tapes. The preform assembly
machine can be scaled to the
number of patches needed
on the preform.

Fig. 2: QSP details

Using a newly developed thermoplastic
pultrusion process, the fibres are impregnated continuously on a large volume of
material. The manufacturer chooses the
fibre/matrix combination and adapts the
size of the resulting tape to the needs of the

final part. This step eliminates the need to
purchase costly semi-products of standard
sizes, many of which are scrapped during
the process. The final forming-overmoulding step allows the manufacture of complex
shapes in a short time, with design freedom
provided by the injection process. This
technology should be the most suitable
for high-volume production. The use
of QSP® preforms opens up significant
optimization potential, compared to woven
organosheets of constant thickness and
orientation.
QSP® provides the following advantages
for automotive applications:
- multi-material parts ready for assembly;

Fig. 3: Patching plan obtained by numerical
optimization

Specific design
method for optimization
For manufacturers, studying the potential
for a process requires the existence of a
numerical design chain. Cetim proposes a
methodology that uses the best available
tools, and focuses its R&D work on further
improving simulation quality. Developing
a new process goes hand in hand with the
development of design know-how to understand how stresses are transferred from
one patch to another. Design robustness
is assessed by integrating the harmfulness
of the discontinuities in the part. Cetim
develops the following tools:
- optimization software (in collaboration
with French aerospace lab Onera) to help
identify the mechanically optimal zones
and orientations for the patches, based on
the functional specifications (Figure 3);
- design software to help validate the
feasibility of a part. Among other things,
the tool enables linking the final 3D shape
and the initial flat preform. In this way, the
designer has all the information needed for
designing to cost. Equivalent tools exist for
other processes (e.g. the wound composite
modeller for the filament winding process)
and can be integrated into simulation software like DS CATIA;

No98 July - August 2015 /

Feature Automotive

short cycle times, using the following steps:
1 - Pultrusion + extrusion: starting from
continuous fibres combined with a thermoplastic material, tapes are produced
at optimized cost in terms of width,
thickness and fibre reinforcement (UD,
weaving, glass and/or carbon);
2 - Cutting: tailored patches defined by a
specific FEA analysis method are cut from
different continuous pultruded tapes;
3 - Preform assembly: an optimized multithickness and multilayer net-shape preform is assembled from the patches;
4 - Fast heating and transfer: the preform
is heated very quickly using a fast, innovative system and then transferred onto the
mould/press by a robot;
5 & 6 - Thermoforming and overmoulding: the heated preform is thermoformed
and overmoulded with a thermoplastic
material, reinforced (or not) in the same
mould, with one-shot assembly operations to obtain a finished part (Figure 2).

jec composites magazine 37



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015

Cover
Edito
Point of view : business development
Contents
COMPANY & BUSINESS
In brief
Cluster
SME
Agenda of Events
APPLICATIONS
Sports & leisure
Safety
Sports & leisure
MARKET
Resins
FEATURE AUTOMOTIVE
Materials
Binder
Additive
CFRP
Epoxy
Hybrid polymer
QSP
CRTP
Rear axles
Tanks
Engines
RESEARCH & DEVELOPMENT
Fractography
Recycling
TECHNOLOGY & INNOVATIONS
Ancillary product
Vision system
Nano
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cover
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Edito
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Point of view : business development
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 5
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Contents
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 7
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In brief
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cluster
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - SME
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 11
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 12
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 13
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 15
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Safety
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad1
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 19
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Resins
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 21
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 22
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Materials
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 24
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Binder
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Additive
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 27
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 28
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 29
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CFRP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 31
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 33
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Hybrid polymer
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 35
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - QSP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 37
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 38
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CRTP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 40
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 41
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Rear axles
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Tanks
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Engines
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 45
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Fractography
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 47
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 48
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 49
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Recycling
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 51
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ancillary product
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 53
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Vision system
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 55
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Nano
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Index
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 59
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 60
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