DC0 Öffentlich - (erberan)
High Volume Automotive Applications Addressed by the Braiding Technology
JEC World Conference 2017
Dr. Andreas Erber | Paris | March, 2017
Page 2 | JEC World Conference 2017 DC0 Öffentlich - (erberan)
Markets
Acrylic Fibers
Automotive
Aerospace & Defense
Wind
Industrial
Business Unit Composites – Fibers and MaterialsOur solutions serve key markets
Unique integrated value chain
Fibers
Materials
Engineered Solutions
Broad portfolio of high-performance products - Acrylic Fibers - Stretch Broken Yarn- Oxidized Fibers - Chopped & Milled Fibers- Carbon Fibers
Production technologies along the fiber value chain - Woven Fabrics - Preforms- Non crimp Fabrics (NCF) - Prepregs & TowPregs- Nonwovens - Tapes & Organo Sheets- Braidings - Wet Friction Materials
Lightweight and Application Center (LAC) In-house bridge between SGL products and customer applications in the development of fiber reinforced composite components - Engineering solutions and manufacturing prototypes (e.g. CFRP Parts)
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Business Unit Composites – Fibers and Materials Production network covers the whole value chain
Precursor and acrylic fibersCarbon fibersMaterialsComposites
RiedOrt
Gardena Arkadelphia
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New electric vehicle concepts with pioneering design
Carbon fiber in automotive series productionBMW i - Born Electric
Source: BMW Group
BMW i3/i8
Series
BMW i3.
BMW i8.
▪ Overall concepts dedicated to battery electric mobility
▪ Structural design aligned with composite requirements
▪ Large scale production of carbon fibers and composites
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CFRP supply chain
SGL Group’s composites in the automotive industry Lightweight expertise for the BMW Group
Source: BMW Group
BMW i3/i8
Series
Precursor Carbon Fiber Production
Textiles and Recycling
Composite Components
BMW i3/ i8 Production
- Japan - - USA - - Germany - - Germany - - Germany -
1 2 3 4 5
2 | Moses Lake
3 | Wackersdorf4 | Landshut
5 | Leipzig
Mitsubishi Rayon-SGL Precursor SGL Group BMW Group
1 | Otake
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SGL Group’s textile material toolboxbased on carbon and glass fibers
Tailored Textiles▪ UD textile▪ Local reinforcement
Fabrics▪ Various textile
architectures▪ Laminar
reinforcement
Nonwoven material▪ Random orientation▪ Based on secondary
fibers and textiles
Preforms▪ Comprising
different textiles▪ Local reinforced
Textiles▪ Carbon and Glass fibers based▪ Various semi-finished materials
as a toolbox approach▪ Bindered textiles for preforming
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Braiding technologyEveryday Life
Principle of hand braiding
Braided bakery product
Source: TU Munich
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Braiding technologyMachine principle - history
Braiding „machine“ from Japan784 - 1185 n.Chr.
• 15th March 1748first reference of machine braiding
• 1780first operational braiding machine
• 1898significant advancement of the horn gear arrangement
Source: TU Munich
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Transmission shafts by braiding technologyExample: Commercial aircraft high lift system
Radial braiding machine (64 carrier)
Biaxial fiber architecture
Triaxial fiber architecture
Differential design:Braided transmission shaft with metallic flanges
High lift system of a commercial aircraft
Source: University Stuttgart
Source: Liebherr Aerospace Lindenberg GmbH
Source: University Stuttgart
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Integral design of transmission shaftsComposite flanges
Integral versusdifferential design
Flanges offer a huge lightweight potential
F
F
Principle of flange manufacturing tool Braiding of flange; step #1 Braiding of flange; step #2Source: PhD Thesis A. Erber
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Integral design of transmission shafts Composite flanges
Challengebearing stress
Non-reinforced flange; 3 x M6
0
100
200
300
400
500
Ve
rsa
ge
ns
las
t [N
m]
200
220
240
260
280
300
Ge
wic
ht
[g]
Versagenslast
Gewicht
Unverstärkt Spiralverstärkung Radialverstärkung
3 x M8
Wei
ght [
g]
Failu
re lo
ad [N
m]
Failure load Weight
Non-reinforced Spiral reinforcement Radial reinforcement
Spiral reinforcement Radial reinforcement Source: PhD Thesis A. Erber
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Industrialized braiding technologyBMW 7 series side roof frame
Significant weight-savings through lightweight chassis
Source: BMW Group
New BMW
7 Series
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Industrialized braiding technology BMW 7 series side roof frame
• Braided side roof frame as reinforcement of a steel sheet
• Overbraiding of a thermoplastic core• RTM process (thermoset matrix)
Industrialization of a hybrid component within a multi-material body in white design.
Source BMW Group
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Serial production at SGL KümpersBraiding of the side roof frame preforms
Source: SGL Kümpers GmbH
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Lightweight and Application Center (LAC)Understanding customer needs
▪ Application of SGL products in customer processes
▪ Characterization of SGL materials for design and process engineering of customer applications
▪ Design and simulation for composite parts
▪ Demonstration of automation and serial production capability
▪ Prototyping and low volume production according customer requirements
Concept development
Design and simulation
Prototyping and testing
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Example: Braided transmission shaft
Lightweight and Application Center (LAC)Understanding customer needs
• Design tools (CAD)
• Laminate design (FEA)
• Process simulation
• Digital manufacturing
Material and preform simulation
Process simulation
▪ Material cards for customer simulation▪ Material characterization with respect to processing▪ Design of structural components, modules and tools▪ Weight and cost engineering of components
System simulation
Design and optimization
Source: PhD Thesis A. Erber
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Lightweight and Application Center Understanding customer needs• Thermoplastic pultrusion• Filament winding• Robot based winding• Wet pressing• Thermoforming• Pick & Place Technologies
Virtual reality: Robotic cell as an example Process Technology