automated composites manufacturing and 4d printing of ......issues with automated composites...

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Suong V. Hoa Department of Mechanical, Industrial And Aerospace Engineering Automated composites manufacturing and 4D printing of composites National Colloquium on Sustainable Aviation- University of Toronto- Institute for Aerospace Studies- June 21-23, 2017

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Page 1: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Suong V. Hoa

Department of Mechanical, Industrial

And Aerospace Engineering

Automated composites manufacturing and 4D printing of composites

National Colloquium on Sustainable Aviation- University of Toronto- Institute for Aerospace Studies- June 21-23, 2017

Page 2: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Outline of presentation

1. Automated Composites Manufacturing and

Sustainability in Aviation.

2. Traditional method of composites manufacturing

3. Need for automation of composites manufacturing

4. Advent of automated composites manufacturing:

ATL and AFP

4. Advantages of automated composites manufacturing

5. Issues and challenges

6. Unique structures –Unique properties

7. 4D printing of composites

8. Conclusion

Page 3: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Automated Composite Manufacturing (ACM) and

Sustainability in Aviation

1. Composites offer light weight.

2. ACM reduces waste.

3. ACM speeds up the rate of production

4. ACM reduces variability.

5. Provides opportunities to develop thermoplastic

composite structures- No shelf life- Recyclability.

6. Facilitates the manufacturing of large

composite structures.

7. Fiber steering- Optimal use of materials.

8. Enable 4D printing (moldless manufacturing)

Page 4: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Traditional method of

composites manufacturing

Hand Lay Up

Preform

Tool

Injection

Ratio Control

Resi

n

Catalyst

Cure

De-mold

Liquid Composite molding (LCM)

Page 5: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Traditional method of

composites manufacturing

Filament winding

Pultrusion

Female

cavity

Male mold

Compression molding

Male mold - bottom Female mold- bottom

Page 6: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Need for automation in the manufacturing of composites

1. HLU rate of material deposition is slow (2.2 lbs/hr). Fuselage of 5 m diameter, 15 m long, 3 mm thick would take 1 worker 1272 hours to lay down.

2. Manual lay up is not practical to lay materials on large structures.

3. Issues with repeatability. Consistency of quality.

4. Material waste. Buy/Fly ratio = 3

A

B

C

D

Page 7: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Industrial machines (mainly focused on high speed of material deposition)

http://concom.encs.concordia.ca

Page 8: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

8

Ingersoll machines

Page 9: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Automated Tape Lay Up (ATL) and Automated Fiber Placement (AFP)

machines

http://concom.encs.concordia.ca

Automated Tape Lay Up (ATL) machine1.Mainly for thermoset lay up2.Lay down wide tapes (tape width up

to 12 inch) 3.Fast lay upAutomated Fiber Placement (AFP)1.Thermoset and thermoplastic

composites2.Can lay down one tow or multiple

tows at once 3.Individual tow cutting capability

Page 10: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

http://concom.encs.concordia.ca

Nitrogen Hot Gas Torch

Laid down thermoplastic composite layers

Incoming composite tape

Steel compaction roller

Tape feeder

Pneumatic cylinder for

applying compaction force

Page 11: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Advantages of automated composites manufacturing

1. Faster rate of material deposition (about 20 lbs/hr

compared to 2.2 lbs/hr for HLU).

2. Reduce debulking time

3. Less manual labor intensive

4. Less variability, better repeatability.

5. Essential to handle large structures.

6. Smoother transition between design and

manufacturing

7. Less material wastage

8. Ability to steer fibers

9. Capability to make unique structures

Page 12: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Less material wastage

Hand Lay Up

AFP

Page 13: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Ability to steer fibers

[0/45/-45/90]s[0/Ɵ/-Ɵ/90]s

Page 14: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Issues with automated composites manufacturing

1. High machine cost.

2. Steep learning curve

3. Expensive operation.

4. Occurrence of laps and gaps

5. Serrated edges at boundaries

6. Defects due to steering.

7. In-plane waviness.

8. Ability to detect defects in-situ

9. Distortion of components made of thermoplastic

composites.

Page 15: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Occurrence of laps and gaps

http://concom.encs.concordia.ca

Page 16: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Serrated edges at boundaries

http://concom.encs.concordia.ca

Page 17: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Defects due to fiber steering

http://concom.encs.concordia.ca

1.Buckling of inner fibers

2.Raised edge-Fish eyes

3.Fold overs4.Limited radius

Page 18: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

In-plane waviness

http://concom.encs.concordia.ca

Page 19: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Distortion of components made of thermoplastic

composites

http://concom.encs.concordia.ca

Structures with free edges (plates, shells, panels) can exhibit distortion- Cold mandrel

Distortion problem can be solved using hot mandrel to make laminates with free edges

Page 20: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Occurrence of voids in thermoplastic composites

http://concom.encs.concordia.ca

Voids can occur on top layers

This problem can be resolved by using repasses- This means slower process

1000 µm

Page 21: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Unique structures- Unique properties

Page 22: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Landing gear

Cross Tubes

Unique structures

Page 23: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Current design-Aluminum 7075-

T6

Advantages :• Very ductile• No abrupt fracture

Disadvantages:• Fabrication process• Spot Corrosion• Cost

Initial state

Severe landing

Page 24: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Composites are relatively brittle

Challenges

Page 25: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Unique structures

Page 26: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4
Page 27: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Three Point Bending test; 4th composite tubeID 56mm, OD 78 mm

Composite tube is 30% lighter than aluminum tube-

Page 28: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Curved tube

Page 29: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Curved thermoplastic composite tube

Page 30: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

Combination of 3D printing and self re-configuration after material deposition.

Exploits the anisotropy of composite materials

4D printing of composites

Page 31: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

http://concom.encs.concordia.ca

3-D

Printin

g

Activation

Process:

Heat,

electricity,

Light,

Moisture,

magnetic fieldSelf-

Reconfigura

tion

Page 32: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

http://concom.encs.concordia.ca

4D printing with composites1. Automated fiber placement machines can be used to deposit layers additively to produce stacks of composite layers.

2. Anisotropic properties of composite materials may be used to produce deformations upon use of heat activation.

3. Structures of complex geometries and good mechanical properties can be made.

4D printing of composites

Page 33: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

http://concom.encs.concordia.ca

Layer 1

Layer 2

0o

0o

90o

90o

Page 34: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

THANK YOU

http://concom.encs.concordia.ca

Page 35: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

http://concom.encs.concordia.ca

Page 36: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

In spite of the many issues that need to be resolved, Automated Composites Manufacturing holds a lot of promise for the manufacturing of composites structures in the future.

Conclusion

Page 37: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

By using anisotropic properties of composites, one can make engineering structures that can re-configure into desirable shape after material deposition using additive manufacturing.

Complex structures can be made without using complex molds

Conclusion

Page 38: Automated composites manufacturing and 4D printing of ......Issues with automated composites manufacturing 1. High machine cost. 2. Steep learning curve 3. Expensive operation. 4

ACKNOWLEDGEMENT

http://concom.encs.concordia.ca

CompaniesBell Helicopter Textron Canada Ltd.Bombardier AerospaceEmergiaDelastekComposites AtlanticAutomated DynamicsCYTEC

Government agenciesNatural Sciences and Engineering Research Council of Canada (NSERC)National Research Council of Canada (AMTC)CRIAQMDEIEIndustrial Research Chair program (NSERC)

Students and associatesBijan DerisiFarjad ShadmehriHoang Minh DucJeff Simpson

Hossein GhayoorMohammad Rouhi

Amir KaganjMohamed Geuchy

Xiao CaiHeng Wang