Abstract
Fiber path optimization methods combined with the Tailor Fiber Placement (TFP) technology provide the optimum correlation between load case and fiber orientation and therefore lead to unmatched component performance with endless fiber composite materials. The aim of this work is the development of an innovative manufacturing technology for thermoplastic composites (TPC) including sizing-adapted commingled glass fiber (GF) / thermoplastic yarns (SpinCom yarns) to be processed by TFP to textile preforms with a variable-axial, load adapted fiber design. Furthermore, these preforms will be consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming technology. Finally, a low cost solution for thermal processing even for complex shaped TPC parts will be presented. Heading towards optimized resource and cost efficiency of the whole process chain, first results of SpinCom yarns, fiber path optimization, tool manufacturing and forming procedure are presented and demonstrated using GF/PBT (polybutylene therephthalate) SpinCom yarns and the geometry of a bicycle saddle.
Highlights
The development of fiber-reinforced plastics (FRP) opens up a high strength, stiffness and lightweight potential for structural components
After spinning and drying the SpinCom yarn bobbins, the behavior during the textile processing is highly dependent on the sizing, since well-running yarns are the precondition for further processing in Tailor Fiber Placement (TFP)
The results of the composites made of SpinCom yarns without sizing contribute to the good processability of PBT2: no significant difference in the strength was found, the standard deviation is strongly reduced
Summary
The development of fiber-reinforced plastics (FRP) opens up a high strength, stiffness and lightweight potential for structural components. In most cases layered structures of unidirectional (UD) yarns, so called multiaxial laminates, are used for composite manufacturing. This is mostly motivated by the availability of textile semi-finished products, e.g. woven and non-woven fabrics, and well-established numerical methods for a multiaxial laminate design. This results in significantly reduced component performances. For simple shapes and plain loads new methods for the design and modeling of variable-axial composite structures made by TFP have been developed recently [1], [2], [3], [4].
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