JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 43

Waste-free composite wheel production

Fig. 2: Example of a CompoSpoke grinding wheel

were previously reserved for metals for
cost reasons. In mechanical and plant engineering, for example, many components
currently made of steel or aluminium
can be replaced with FRP components.
Applications are mainly found in markets
where machine parts are exposed to high
loads or where lightweight construction is
especially important.
Compared to conventional materials such
as steel, the mass of FRP machine components is significantly reduced for the
same load capacity. A machine design with
smaller drives and brakes can save further
resources, particularly in situations where
wheels are continuously accelerated and
decelerated.
To illustrate these advantages, take the
example of a high-performance grinding
wheel used in the automotive industry to
grind bearing seats (Figure 2).
In the particular example of a wheel with
a 400mm diameter and a 30mm thickness,
there are vast weight differences depending
on the materials and production methods
used. Traditionally designed and built
in steel, the body of the grinding wheel
weighs more than 25kg without the grinding layer and tool fitting. This high weight
not only results in handling problems but
also in higher energy consumption during
use. The same wheel body built with commonly used FRP manufacturing is already
much lighter. Using a solid stack of carbon
fabric, the weight comes down to 3kg. Yet,
with CompoSpoke this already low weight
can be further reduced by almost 50%
down to only 1.6kg for the entire body.
Consequently, the CompoSpoke body is
80% lighter compared to the steel version.

Focus
The CompoSpoke technology is exclusively used by Evolime Radial
Composites, a spin-off from the Institute of Composite Materials at
the Technical University in Kaiserslautern (Germany). The technology's
development is funded within an EXIST Research Transfer (2019-2020)
by the Federal Ministry of Economics
and Energy of Germany (BMWi) and
the European Social Fund.

Conclusion
Significant material and energy savings
results in clear productivity advantages
when using machinery. Lightweight wheel
structures can add their share to save
resources in many industries.
With the selection of specific of fibres and
a suitable geometry, CompoSpoke makes
it possible to manufacture FRP wheel
structures with very low weight and hardly
any production waste.
Thereby, it shifts the focus towards a
more comprehensive view of resource
consumption when manufacturing and
using FRP wheels.

N°136 September - October 2020

More information:
www.evolime.de

References
[1] https://presse.porsche.de/prod/
presse_pag/PressResources.nsf/
content?ReadForm&languageversionid=767979

/ jec composites magazine

Feature Sustainability

Moving towards sustainability
The process has several advantages in terms
of production and cost efficiency. With
regard to sustainability issues, primary and
secondary effects can be distinguished.
Primary effects arise in its advantages
related to the manufacturing process as
compared to established methods and
procedures. Common FRP wheels usually
consist of a large number of pieces cut from
semi-finished products. A high resource
consumption is evident not only when
producing these fabrics, but also when
cutting the different layer geometries from
the textiles. To better illustrate how many
pieces are needed to manufacture such a
wheel, take the example of the German
high-performance sports car manufacturer, Porsche. The company explains that
the wheel centre of their newly-developed
FRP wheel for the 911 Turbo S "[...]
involves cutting and assembling over 200
individual components."[1] Additional resources are needed when manually putting
these pieces together. It is evident that
such a procedure is hardly able to conserve
material and energy resources.
By contrast, CompoSpoke manufactures
the entire wheel from a single continuous
fibre roving. Not even multiple positioning
of the fibre roving is necessary. Thus, the
entire component can be manufactured
without any material loss. Material is
neither wasted during production nor for
setting up the machine. Even though the
procedure is not compatible with every
spoke geometry, an appropriate solution
can be found for many applications. The
optimized use of raw materials makes the
process competitive even when compared
to metallic construction methods. This is
particularly the case when, due to small
batch sizes, casting of metallic components
close to the final contour is not a suitable
option. For instance, the material input
of milled components and the energy required to recycle the chips are significantly
higher.
Secondary effects arise as lightweight
construction offers further energy saving
potential throughout the component's
life cycle. Thanks to the material-efficient
and automatable manufacturing process,
CompoSpoke can bring fibre-reinforced
plastic composites into applications that

43


http://www.evolime.de https://presse.porsche.de/prod/presse_pag/PressResources.nsf/content?ReadForm&languageversionid=767979

JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Reinforcement - Natural-fibre composites: an overview
Startup - When 3D printing meets sustainability
China - Xinzhou bets on the bamboo-based composites industry
MANUFACTURING
Wind - lnnovation in wind power through multi-process-capable systems
Automation - Higher production capacity thanks to automated manufacturing
FEATURE Sustainability - The path has been plotted
Recycling ecosystem - Composites recycling: in search of the circular economy
Mobility - A new generation of recycled composite materials for sustainable mobility
Preimpregnated textile - Healable composites to improve circularity
Process - New trends in composites and plastics recycling
Raw materials - Innovative composites made from up to 92% reclaimed materials
Construction - Biocomposites and automation: a sustainable future for the building industry
Ressources - Waste-free composite wheel production
Wind energy - From bottle to blade
Durable composites - Upcycling plastic bottles into value-added composite applications
Matrix - Novel thermoset composites for more competitive and sustainable industries
SOLUTIONS
Aerospace - Slinging rockets into space
Aerospace - Composites push back the final frontier
Railway - Composite overhead line catenary system for light rail
TECHNOLOGY
Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
Inside the lab - Advanced Composite Materials Facility University of Southampton
Resin - Development of new type of plastics: Polypropylene 2.0
Index
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JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Reinforcement - Natural-fibre composites: an overview
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Startup - When 3D printing meets sustainability
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - China - Xinzhou bets on the bamboo-based composites industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 17
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind - lnnovation in wind power through multi-process-capable systems
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 19
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 21
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Automation - Higher production capacity thanks to automated manufacturing
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 24
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Recycling ecosystem - Composites recycling: in search of the circular economy
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 30
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Mobility - A new generation of recycled composite materials for sustainable mobility
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Preimpregnated textile - Healable composites to improve circularity
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 34
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Process - New trends in composites and plastics recycling
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 37
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Raw materials - Innovative composites made from up to 92% reclaimed materials
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 39
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Construction - Biocomposites and automation: a sustainable future for the building industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Ressources - Waste-free composite wheel production
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind energy - From bottle to blade
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Durable composites - Upcycling plastic bottles into value-added composite applications
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 47
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Matrix - Novel thermoset composites for more competitive and sustainable industries
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Slinging rockets into space
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 52
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Composites push back the final frontier
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Railway - Composite overhead line catenary system for light rail
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Inside the lab - Advanced Composite Materials Facility University of Southampton
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Resin - Development of new type of plastics: Polypropylene 2.0
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 68
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