Post on 02-Aug-2018
Elastomers as a flexible tooling surface
Vacuum Assisted Multipoint Tooling for Producing
Spatially Curved Single-Item CFRP Panels
Matthias Wimmer
Munich University of Applied Science
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
... if a flat piece costs one dollar and a single curvature piece costs two dollars then a double curvature piece costs ten dollars. This is true for all materials wood,
metal, plastic, glass, concrete ...
05.07.2016
2
Lindsey, Bruce; Gehry, Frank O. (2001): Digital Gehry. Material resistance, digital construction. Basel: Birkhäuser
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Overview
multipoint tooling
manufacturing of CFRP panels
challenges and solutions
conclusion and outlook
05.07.2016
3
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
MULTIPOINT TOOLING
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Basic Idea
05.07.2016
5
Curtis Lawrence (2008), Pinpression Animated, Youtube.com
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Basic Idea
05.07.2016
6
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
First invention
05/07/2016
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Cochrane, John (1862): Improvement in presses for bending metallic plates, US patent 39,886
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Concept
05/07/2016
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solid mould multipoint tool
interpolation layer
(elastomer)
pin array
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Recent Developments
05.07.2016
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3D Former for manufacturing PMMA windshields (Munich University of Applied Science, 2009)
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
MANUFACTURING OF CFRP PANELS
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Manufacturing Processes
wet layup vacuum bagging
vacuum infusion prepreg moulding
05/07/2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Process Chain
Part design
•CAD design
Mould design
•warp calculation •CAD mould
design
CAM
•CNC programing
Mold manufacturing
•milling •grinding•polishing
Part manufacturing
•application of release agent•fabric layup•curing
Moulds end of life
•mold storage•mold revision•recycling
05.07.2016
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1-5 days 1 day 1-2 days 1-2 days
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
CHALLENGES AND SOLUTIONS
05/07/2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Challenges in tool design
existing tools are limited in geometric complexity
only convex shapes can be created
standard CFRP manufacturing processes are not usable
shape accuracy of at least .5 mm has to be achieved
elevated temperatures destroy interpolation layer
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Vacuum Assisted Multipoint Moulding
05.07.2016
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interpolation layer in tenter frame
pin array
threaded rods
vacuum container
base plate actuator couplings
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Challenges to achieve high quality
dimpling
shape deviation
05/07/2016
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desired shape
actual shape
Source: Dunarea de Jos University of Galati
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Ideal interpolation layer
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Single Layer IPL
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Single Layer IPL
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Single Layer IPL
05.07.2016
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Dimpling [mm]
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Simulation results
05.07.2016
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30
35
40
45
50
55
0 10 20 30 40 50 60 70 80
Y [
mm
]
X [mm]
Sphere with radius 218 mm with different IPL thicknesses
24 mm
18 mm
12 mm
6 mm
desired shape
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Exemplary measurements
15 mm
10 mm
5 mm
300mBar 600mBar 900mBar
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Interpolation layer
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Shape deviation control
Closed Loop shape control using FEA model of theforming process
05.07.2016
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Valjavec, Marco (1999): A Closed-loop Shape Control Methodology for Flexible Stretch Forming over a Reconfigurable Tool. Massachusetts Institute of Technology (MIT), Cambridge, Massachusetts
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Simulation results
05.07.2016
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30
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40
45
50
55
0 10 20 30 40 50 60 70 80
Y [
mm
]
X [mm]
Sphere shape (r=218 mm) with different IPL thicknesses –shape error corrected
24 mm
18 mm
12 mm
6 mm
desired shape
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Proposed solutions
Multi layer IPL:
Soft, incompressible material in low layer too fillgaps
Hard material on top too smoothen out dimplesand create a viable surface
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Multilayer IPL
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
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40
45
50
55
0 10 20 30 40 50 60 70 80
Y [
mm
]
X [mm]
Sphere with radius 218 mm with 12 mm IPL (single/multilayer)
desired shape
multilayer 10+2
12 mm
Multilayer IPL
05.07.2016
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Dsl
Dml
Serr_slSerr_ml
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Manufacturing test
Picture of produced part (with grid on it?)
05.07.2016
29
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Reference part
05.07.2016
30
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
CONCLUSION AND OUTLOOK
05/07/2016
31
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Conclusion
Dimpling is a problem in vacuum assisted multipoint tooling.
With a single layer of the tested material an interpolation layer thickness equal to the pin diameter is sufficient to prevent dimpling in vacuum assisted multipoint tooling.
The multilayer approach can decrease dimpling more sufficiently than a single layer IPL.
05/07/2016
32
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Outlook
testing of the IPL behaviour with real materials and measured material parameters
sensitivity analysis of different parameters influencing IPL behaviour
numeric optimization of the layer design
reverse engineering of materials for use in multilayer IPL
manufacturing and test of multilayer IPL
05.07.2016
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Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Outlook
05.07.2016
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Part design
•CAD design
CAM
•Warp calculation•Pin position
extraction
Tool setup
•Pin adjustment
Part manufacturing
•fabric layup•curing
1 hour 1-3 hours 1-2 days
Part design
•CAD design
Mould design
•warp calculation •CAD mould
design
CAM
•CNC programing
Mold manufacturing
•milling •grinding•polishing
Part manufacturing
•application of release agent•fabric layup•curing
Moulds end of life
•mold storage•mold revision•recycling
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Outlook
05/07/2016
35
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Thank you very much.
05.07.2016
36
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, Matthias.Wimmer0@hm.edu
Contact
05.07.2016
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Matthias WimmerResearch Assistant
Project FlexForCFK
Competence Centre for Product- und Organisation Development
Dachauer Str. 98b | 80335 Munich | Germany Telephone: +49 (0) 89/1265 - 3389E-Mail: Matthias.Wimmer0@hm.edu
Competence CentreProduct and Organisation Development