Systematische Technologiekettengestaltung für endkonturnahe Strukturbauteile mittels Tailored Fibre Placement

  • Systematic technology chain design for near-net-shape structural components using tailored fibre placement

Schwab, Max Ferdinand; Gries, Thomas (Thesis advisor); Herrmann, Axel (Thesis advisor)

Düren : Shaker Verlag (2021)
Book, Dissertation / PhD Thesis

In: Textiltechnik/Textile technology
Page(s)/Article-Nr.: III, 227 Seiten : Illustrationen, Diagramme

Dissertation, RWTH Aachen University, 2020

Abstract

Tailored Fibre Placement (TFP) is a process by which textiles for fibre-reinforced plastics (FRP) can be produced in a load-bearing and near-net-shape manner (fibre waste < 5 %). Due to the complex component design and the lack of knowledge management, TFP technology is rarely used for FRP components, despite mature machine technology. Currently there is no uniform, systematic procedure with which process chains for TFP component production can be designed. In this work, the holistic design of technology chains is developed by considering the process steps impregnation and consolidation to the final FRP component in order to exploit the high lightweight construction potential of the TFP process. The use of the TFP process reduces fibre waste and thus the costs for semi-finished products. For this purpose, a six-step methodology for designing the technology chain for TFP components is developed, which considers the entire process chain from the fibre to the final FRP component and is based on integrated and operative technology planning. A systematic procedure for efficient and well-structured process planning is established. The developed methodology is applied to three industry-oriented components (seat spreader, wheel arch and convertible roof). Thus, new, innovative and holistic technology chains for TFP components are designed and compared with reference materials. The results of the technical-economic comparison show an increase in performance (15 %) and functionalisation (100 %) of the components with simultaneous cost advantages (12 %). Fibre waste is reduced by up to 30 % by using TFP technology. Compared to conventional technology chain design, there are no iterations in component design and TFP preforming, so that the process planning effort can be reduced by up to 30 %. Thus, the effectiveness and efficiency of the developed methodology can be demonstrated. Due to the well-structured process planning, new combination possibilities for the production of functionalized, innovative TFP components can be generated.

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