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Page 3 How to produce a net shape Thermoplastic Composite part in one minute with the QSP ®
Page 3
How to produce a net shape
Thermoplastic Composite part in
one minute with the QSP®
2
A regional, national and international player:
115 M€ turn over,
900 employees,
8 sites in France,
44,000 m² of laboratories and platforms
3 subsidiaries in France and North Africa
Part of a strategic French R&D network:
Covering all topics in the mechanical field with 9 open labs with universities
Paving the way to innovative technologies on the whole product’s lifecycle
A strategy geared around innovation: R&T development & support for more than 4,000 customers per year Acting in standardization committees (216 seats)
Cetim the french innovation maker in mechanics
3
Cetim Composite at a glance
Cetim composite expertise and work Force
Polymer Material expertise for 40 years
+120 PhD, Engineers and Technicians
18M€ turn over in composite activity
Scientific partnership with: ECNantes,
ENSCachan, Onera, Imperial College of London…
Industrial partnership with AFPT for Spide TP
and Pinette, Loiretech and Compose for QSP
4
QSD®
Quilted Stratum Designfor
Part Design & Process Industrialization
How to optimize weight reduction part
on composite part / FEA simulation?
5
Exemple de reconception d’une ferrure titane
Adaptation des formes aux procédés composites :
Support titane
Interfaces fonctionnelles Support CompositeDesign intermédiaires
Tenue de objectifs en raideur et en dilatation thermique
Réduction masse 20%
Réduction coût 40%
6
FEA SIMULATION - Cetim development : QSD® OPTIM
Quilted Stratum Design Optimization
7
QSD® “Optim”: Bi-level optimization
stategy for multi-thickness lay up
Best material
= Isotropic
Best material
= orthotropic
𝑬𝟏𝟏 𝜽Number of plies
(=Thickness)
Number of iteration
Weight
Max c
onstr
ain
t vio
lation (
%)
Bending Stiffness
Membrane Stiffness
Level 2. Mesoscopic optimization
with Stacking Sequence Table
Practical design: laminates plybook
• MATLAB routine to evaluate the best
Stacking Sequence Table
• Evaluation to choose according process
recommandation
• Then Verification by FEA (Abaqus, Altair®
OptiStruct® , …)
Level 1. Macroscopic
optimization with homogenized
material
Research of optimal thickness
distribution & stiffness distribution:
- using the method of feasible
directions implemented in Altair®
OptiStruct® (FEA).
- MATLAB program for automatic
data implementation of Lamination
Parameters
in partnership with
Objective = Min (weight)
An optimization with algorithms to choose the best shape and build the best plybook
8
Exemple de conception d’un dossier de siège
automobile
1,5mm
2mm
3mm
Layer 4 Layer 5 Layer 6
Fabric 0°/90°
0,5mmFabric 0°/90°
0,5mmFabric 45°/-45°
0,5mm
Layer 1 Layer 2 Layer 3
Fabric 0°/90°
0,5mmFabric 0°/90°
0,5mmFabric 45°/-45°
0,5mm
Adaptation de
l’empilement à
l’objectif coût :
Pas de pli continu
Épaisseur variable
Orientation optimale
9
Corrélation essais calculs
Identification inverse de comportement
par corrélation calculs/essais
Simulation des essais pour définir
l’instrumentation la plus adaptée
10
QSP®
One minute multi-thicknesslayer preform assembly
« From fibers to net shape part »
11
Quilted Stratum Process® (QSP®) : A team success
Started in 2013 from concepts
To a new pilot
production line
installed in 2015
And the product demonstration
in 2016with the low cost
composite bumper beam
12
Design optimized, the right material at the right place : Multi-thickness parts
Multi-orientation parts
Multi-material parts
Netshape final parts for more added value : Global integration from raw material to final parts
Low material scraps
Assembly & functions integration
Production performance :
Full automated cell from preform assembly to netshape part
Short cycle time (40 to 90sec)
Competitive cost
Quilted Stratum Process® (QSP®) : A new concept
13
General possibilities of the QSP®
THERMOFORMING & OVERMOULDING
To add a maximum value intra-mold
& get a netshape part
RAW MATERIALS
Fibers & Thermoplastic
HIGH SPEED CUTTINGTo cut all patches needed for the multi-thickness preform
TP PULTRUSIONTo create semi-products with a low cost and high
speed of production FAST HEATINGCombining conduction & High-Speed IR ovens for multi-thickness preforms
PREFORM ASSEMBLYTo make an automated assembly of a multilayer “netshape” preform < 1min
HIGH SPEED TRANSFER< 5sec
Any other organosheets or tapes
14 Production performance :
Production speed : From 1 to 5 m / min
Competitive cost Speed = the key parameter
Quality of tapes :
Glass fibers from 45 to 55% of volume
Carbon fibers from 60 to 70% of volume
Matrix layer on surface (improve the
inter-tape welding)
Low porosity rate < 2,5%
Pultrusion thermoplastic
0
5
10
15
20
25
0 1 2 3 4 5 6
Cost€/kg
Pultrusion Speed : m/min
Tape width = 100mm
0,5 mm
1 mm
1,5 mm
2 mm
Thickness
Target 2017
1mm
0
5
10
15
20
25
0 1 2 3 4 5 6
Co
st €
/kg
Pultrusion Speed : m/min
Tape width = 200mm
0,5 mm
1 mm
1,5 mm
2 mm
Thickness
Target 2017
15 Flexible technology :
2D straight or curve cutting
Thickness from 0,15 to 5mm
Sheet maxi 1300 x 950mm
Rolls up to 315mm width
High-speed technology :
Cutting speed up to 500mm/sec
Example for a UD Glass fiber - PA6 : 1,5mm thickness cut in one way
Speed = 400mm/sec
Cutting quality :
Clean technology no dust, no water…
Limited burr
Cost :
0,01 to 0,05 € / 100mm cut
Cutting machine
16 Production performance :
From cut patchs to final preform
Full automated cell in line with press
Short cycle time < 60sec
Flexibility of the machine :
Size 1300 x 950mm
8 layers & 4 tapes / layer
Example on QSP multi-
thickness part : 8 layers / 13 patchs
Thickness from 2,5mm to 3,5mm
Multi material preform
Multi-orientation preform
Preform assembly < 60sec
Preform assembly machine
Example of QSPmulti-thickness part :
17 Production performance :
Robust technology combination
Heating technology with patented
specifications
Short cycle time to heat multi-
thickness preforms
Example on QSP part = 50sec
Allows cycle time close to 60sec
Quality / preforms heated :
Reduction of oxidation on PA
Humidity PA after heating process
< 0,2% (mass) :
Even if saturation before
Thermography after heating :
+/- 15°C observed PA6GFmulti-
thickness part (from 2,5mm to 3,5mm)
Heating process
0
50
100
150
200
250
0 10 20 30 40 50 60 70 80 90 100 110 120
Tem
pe
ratu
re (
°C)
Time (s)
Classic temperature evolution / process QSP®
Material = PA6 - Glass Fiber / Thickness min = 2,5mm, max = 3,5mm
Surface3,5mm
Pre-heating - conduction= 46sec
Tran
sfer
Final heating - IR= 50sec
Hig
h-s
pee
d t
ran
sfer
= 5
sec
18 Production performance :
High speed transfer :
< 5sec after heating / press closed
A minimum temperature loss
during transfer :
≈ 15°C lost during transfer between
IR oven and press on QSP part
example
Flexibility of the machine :
Specific gripping hands available
High resistance temperature
needles
High resistance temperature
vacuum systems
Preforming during transfer
possible with gripping hands
High speed transfer with robot
19 Production performance :
From cut patchs to final preform
Full automated cell in line with press
Short cycle time < 90sec
Capacity of the press :
500T vertical press
Krauss Maffei injection unit
Roctool generator 200kW
Tooling expertise
Ex: Preform removal system / mold
Partner :
Forming netshape
20
QSP®
Ready for direct assembly
How to produce net shape part / No machining operation added ?
In mold process insert assembly
21 Creation of holes “one-shot” during the forming process
More added value with a minimum cost
No waste of material, re-use for reinforcement
A minimum damage on fibers to increase mechanical performances
Assembly & function integration in-mold
-
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
drilling after forming one shot holewithout compacting
one shot holewith compacting
Values of tensile strength (compared to complete part without hole) :
𝝈𝑵/𝝈𝟎
22 After molding technology to integrate thread in composite part :
Hole creation intra-mold + BOLLHOFF RIVKLE® SFC setting
Assembly & function integration in-mold
Insertion of RIVKLE® SFC
Smart For Composite - BOLLHOFF
Suppression of radial stresses
Axial stresses only
Stresses uniformly distributed on a ring
Distance to edge reduced
Provides a greater hole tolerance
23 In molding technology to integrate thread in composite part :
Overmolding insert during forming process
Direct insertion of IMTEC® (Böllhoff) through the composite, with one shot overmolding
A maximum added value with a minimum cost & final part ready for assembly
High strength and energy absorption
Assembly & function integration in-mold
0
500
1000
1500
2000
2500
3000
3500
4000
Drilling after forming+ RIVKLE SFC M6
One shot hole compacted+ RIVKLE SFC M6
IMTEC insertion one shot(no hole before) + overmolding
Forc
e (N
)
Pull through results on PA6GF, thickness 1,5mm
Force (N)
-00
500
1000
1500
2000
Allongement (mm)-0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
24 QSP®
The low cost composite bumper beam
25
From metal to multi materials
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Conception:Méthodologie Quilted Stratum Design®
Mas
se
Itérations
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Simulations:
Simulation du formage
Identification zones critique formage
Optimisation forme netshape
Simulation des scénarios de crash
Vérification des critères d’absorption d’énergie
Loi de comportement du composite en crash
Chainage numérique :
– Position des patchs
– Orientation des fibres
Patchs de renforcement
Choc bumper
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Industrialisation: outillage de thermo-estampage
Fabrication d’une pièce « net-shape »
formage + surmoulage
Réalisation de perçages « one-shot »
intra-moule
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Fabrication Quilted Stratum Process®
Opérations:
Temps de cycle = 120 sec
Contrôle IR en ligne:
Pultrusion
Nappage
Découpe
Formage
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Poutre de parechoc – Résultats
Résultats :
2 scénarios de crash validés sur 3
Réduction de masse de 28%
Cout série pièce composite ≈ 10€
Cadence validée = 300 000 p/an
Perspectives du projet
Optimisation pour valider le dernier scénario crash
Validation TRL 6
Proposition aux constructeurs par
Mise en place de QSP série par
