HP- RTM Process Advancements
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1 HP- RTM Process Advancements
2 High Pressure Resin Transfer Molding Process Advancements Authors: Matthias Graf Dieffenbacher GmbH+Co. KG, Heilbronner Str. 20, Eppingen, Germany, Erich Fries Josef Renkl Prof.Dr. Frank Henning Raman Chaudhari Bernd Thoma Krauss Maffei Technologies GmbH Krauss-Maffei-Straße 2, München Fraunhofer ICT, Joseph-von-Fraunhofer- Str. 7, Pfinztal, Germany, 10th ACCE, Sept 2010, Troy (MI) Seite 2
3 Content RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 3
4 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 4
5 Unbeatable combination of properties RTM (Resin Transfer Molding) Basic advantages 1. Excellent Part properties 1. distinguished mechanical properties bidirectional high surface quality paintable on both part sides 2. Stable Process High repeatability RTM 3. High Productivity 2. Self cleaning Mixing head Stable temperature control inside the metering machine up to 120 C 3. relatively short cycle times compared to LP process IMP Possible high degree of automating possible Seite 5
6 Unbeatable combination of properties RTM (Resin Transfer Molding) Basic advantages Fiber contents up to 70 weight percentage with RTM Material: EP Epoxy or Polyurethane resin Glass, Carbon fibers Fiber length: Start length Length in part 50 mm - 50 mm - Benefit: Defined fiber orientation Unsolvable binder High mechanical properties (directional) Low specific weight High fiber contents Typical application Utility vehicles and trucks Aircraft & helicopter (Carbon) Optical (visual) parts Seite 6
7 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 7
8 RTM Process Technology Various Liquid composite molding processes 1. Vacuum infusion process - VIP Vacuum Resin Vacuum Semi finished cuts Preform Preform placement on mold Cover preform with vacuum film Apply vacuum; inject resin; impregnation and curing Cured component 2. Resin transfer molding - RTM Resin Semi finished cuts Preform Preform placement in matched rigid mold Inject resin; impregnation and curing Cured component 3. Vacuum assisted resin transfer molding - VARTM Resin Vacuum Vacuum Vacuum Vacuum Semi finished cuts Preform Preform placement in matched rigid mold; apply vacuum Inject resin; impregnation and curing Cured component Seite 8
9 RTM Process Technology HP- RTM Process High pressure injection RTM HP-RTM Vacuum Vacuum Resin Vacuum Semi finished cuts Preform Cured component Apply high Preform placement in Inject resin at high compression force matched rigid mold; pressure ( bar); Complete impregnation apply vacuum impregnation and curing Advantages of High Pressure RTM: Rapid mold filling Improved impregnation quality Accelerated resin reactivity system can be applied short cycle time Significant reduction of air entrapments and voids Excellent surface properties Low tolerance in thickness and 3D shape High process stability and repeatability Use of internal release agent self cleaning system Seite 9
10 Potential for lightweight design RTM Industries Automobile Trucks Train Boat/ Shipbuilding Aerospace Agricultural equipment Seite 10
11 Target Light weight design Structural Body parts Underbody structure Side Frame Audi R8 Spyder Bumper BMW M6 Roof BMW Project I CityCar Bild Quelle Internet Seite 11
12 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 12
13 Cooperation KraussMaffei - Dieffenbacher Turn Key supplier for RTM application Seite 13
14 Cooperation KraussMaffei - Dieffenbacher Turn Key supplier for RTM application Tank /Storage System Pre-forming Metering technology Press process Mixing head Line Automating Post Treatment Bild Quelle Internet Line Control Tooling Tool Cleaning Seite 14
15 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 15
16 RTM Process Process Chain Draping and Preforming Handling of Fabrics Layup and Fixing Net-Shaping of Preform Preform Handling into Press Mold Closure of Press Mold Contur Cutting Unrolling of Fabrics Fiber Fabrics Resin Injection Unloading and Finishing Mold Cleaning Finished RTM Part Seite 16
17 RTM Process Process Chain Layup and Fixing Handling of Fabrics Draping and Preforming Net-Shaping of Preform Preform Handling into Press Mold Closure of Press Mold Contur Cutting Unrolling of Fabrics Fiber Fabrics Resin Injection Unloading and Finishing Mold Cleaning Seite 17
18 RTM Preforming Definition of product requirements 40 mm mm 90 mm mm Materials: Woven fabrics Fiber material Binder material Size: Dimension x mm Height 100 mm Thickness 2.5 mm Layup: Number of layers Type of fabrics Local reinforcement Inserts Seite 18
19 RTM Process Line Layout Seite 19
20 RTM Preforming Cutting Possibilities - Overview Cutting Mechanical Other / Energy CNC stamping cutting blade Roll cutting circular blade Ultrasonic Laser Plasma Cutting device and cutting knife depends on used material Seite 20
21 RTM Preforming Cutting Unit Cutting Bridge Mechanical CNC stamping cutting blade Roll cutting circular blade Ultrasonic Seite 21
22 RTM Preforming Gripper Overview Gripper non-positive-locking adhesive-locking positive-locking vacuum electrostatic molecular mechanical vacuum gripper Bernoulli electr. adhesion adhesion film freeze gripper needle gripper grate gripper Seite 22
23 RTM Preforming Fixing of Fabrics - Possibilities Fixing of Fabrics chemical thermal mechanical bonding welding stitching needling knitting powder binder fleece binder hot glue liquid binder thermoplastic fiber thermoplastic resin classical stitching one-sided stitiching Seite 23
24 RTM Preforming Handling 2D Shape 3D Shape Robot Gripper CF Cutting table / lamination table Preforming tool n lay-up 1 lay-up Single fabrics Fixed Multi layer fabrics Seite 24
25 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 25
26 RTM Dosing Systems Pump Dosing Maschine Seite 26
27 RTM Dosing Systems New Metering concept from 20g/sec to 200g/sec Release agent Dosing Special Working Tanksystem Vacuum system Refilling by Vacuum Direct feeding to mixing head increase de-molding properties Heating chamber Special Working Tanksystem Free selectable part counter Variable shift classification Trend diagram Profile data recording Maintenance plan Failure protocol Administration of up to 512 different foaming programs Preheating of 200l Barrel Constant temperature control up to 120 C Hydraulic System Strong system to realize multi point injection Seite 27
28 RTM Mixinghead High Pressure Mixingsystem Outstanding Lifetime due to intelligent composition of special materials and surface treatments Impingement Mixing Self cleaning system No static mixer necessary up to 120 C working range suitable for high speed system Release agent dosing direct at Mixing head amount adjustable Controlled by PUC 07 no contamination of material at working container Seite 28
29 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 29
30 RTM Tool Design Tool design by KraussMaffei Sealing Concept Special sealing concepts for low viscose RTM systems Vaccum System Patented Vacuum system to ensure 100% resin filling Integrated Pressure measurement to ensure 100% filling of cavity minimize rejection Multi Mixing head injection Tool can be prepared for x numbers of mixing heads (pressure reduce filling process) Seite 30
31 RTM Material Advantages RTM Technology and Applications Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 31
32 RTM Press Concept Overview Fully automated press concept for large production volume. Key features: High Pressure process for fast reacting resins and high surface quality High precision and high speed leveling system Full automation and process control Seite 32
33 RTM Press Concept Compress Plus Hydraulic Press System: COMPRESS PLUS Energy efficient ram closing Short stroke cylinders with mechanical locking system Seite 33
34 RTM Press Concept Parallel Leveling System High speed High precision leveling system flow control and process control high accuracy in part thickness Seite 34
35 RTM Press Concept Press Automation Fully automated system including: Preform handling into the mold Mold transfer into the press Resin injection Unloading of finished part Transfer into rack Mold cleaning Complete process control Seite 35
36 RTM Material Advantages RTM Technology and Applications RTM Cooperation Dieffenbacher Krauss Maffei RTM Preforming RTM Dosing Systems RTM Tool Design RTM Press Concept RTM Machining Seite 36
37 RTM Machining Solution using Robots 3D-Simulation Knife Cutting Machining Center Interior Offline-Programming Handling Seite 37
38 RTM Machining Machine concept CF-structure parts Machine with horizontal turning wall and 2 robots Technic-Rack on back frame Mobile Robot-cell Tool changing system Modern waste management Horizontal-turning wall Working range BxH 3000x1600 mm Complete open operators area Seite 38
39 Thank you for your attention Seite 39
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