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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, [email protected]
... 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, [email protected]
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, [email protected]
MULTIPOINT TOOLING
05.07.2016
4
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
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, [email protected]
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, [email protected]
First invention
05/07/2016
7
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, [email protected]
Concept
05/07/2016
8
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, [email protected]
Recent Developments
05.07.2016
9
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, [email protected]
MANUFACTURING OF CFRP PANELS
05.07.2016
10
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Manufacturing Processes
wet layup vacuum bagging
vacuum infusion prepreg moulding
05/07/2016
11
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
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
12
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, [email protected]
CHALLENGES AND SOLUTIONS
05/07/2016
13
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
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
14
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Vacuum Assisted Multipoint Moulding
05.07.2016
15
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, [email protected]
Challenges to achieve high quality
dimpling
shape deviation
05/07/2016
16
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, [email protected]
Ideal interpolation layer
05.07.2016
17
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Single Layer IPL
05.07.2016
18
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Single Layer IPL
05.07.2016
19
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Single Layer IPL
05.07.2016
20
Dimpling [mm]
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Simulation results
05.07.2016
21
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, [email protected]
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, [email protected]
Interpolation layer
05.07.2016
23
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Shape deviation control
Closed Loop shape control using FEA model of theforming process
05.07.2016
24
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, [email protected]
Simulation results
05.07.2016
25
30
35
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, [email protected]
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
26
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Multilayer IPL
05.07.2016
27
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
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 12 mm IPL (single/multilayer)
desired shape
multilayer 10+2
12 mm
Multilayer IPL
05.07.2016
28
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, [email protected]
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, [email protected]
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, [email protected]
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, [email protected]
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, [email protected]
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
33
Hier wird der Titel der Präsentation wiederholt (Ansicht >Folienmaster)Elastomers as a flexible tooling surface
Matthias Wimmer, Department of Mechanical Engineering, [email protected]
Outlook
05.07.2016
34
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, [email protected]
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, [email protected]
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, [email protected]
Contact
05.07.2016
37
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: [email protected]
Competence CentreProduct and Organisation Development