Cevotec通過多材料鋪設擴大了夾層結構的應用范圍
光纖貼片放置（FPP）已成為復雜纖維復合材料部件自動化生產的選技術。具有適當尺寸的貼片的部件的增材制造尤其用于航空航天和汽車工業，醫療設備和運動設備。通過與的航空航天工業零部件制造商的密切合作，Cevotec根據行業要求進一步開發整個貼片貼裝工藝。
Cevotec的FPP專家對復雜的夾層部件及其復雜的材料混合物特別感興趣，如粘合膜，玻璃纖維和碳纖維層。這些不同的材料用于改善碳纖維材料與常用的鋁蜂窩夾層芯的粘合性和可加工性。
“我們目前正在開發的SAMBA Multi生產系統能夠在一個系統中自動鋪設這種特殊的多材料混合物，”Cevotec席技術官Felix Michl表示。
除了玻璃纖維羊毛，金屬結構和木芯，蜂窩芯，固體泡沫和其他材料已經享受了負載調整的纖維補片增強。根據工藝要求，可以在線生產或與生產線并行完成，以優化循環時間。
SAMBA Multi具有用于不同材料的平行進料裝置，這些裝置在一個生產系統中加工并精確放置在三明治芯或預成型工具上。通過將FPP單元安裝在線性軸上，該概念還使得能夠在航空航天應用中生產特別長且寬的部件。根據特定的元件尺寸，我們還根據DIN-A5和DIN-A4尺寸調整貼片夾具，以滿足普通飛機部件的要求。集成的夾持站可在此過程中更換夾具。
“復雜夾層部件的自動化多層材料鋪設對加工時間和生產量產生了極為積極的影響，”Cevotec董事總經理Thorsten Groene解釋道：“壓力和熱量受控的纖維沉積能夠避免中間壓實因此，Groene繼續說道，FPP可持續地降低許多應用中的經常性生產成本。當然，材料節省20％ - 50％起著重要作用，但FPP自動化通?？梢赃M一步優化整個過程。“
SAMBA Multi的另一個優點是生產過程的高可擴展性。“同一個過程每年都會產生幾百到幾千個單位，”Michl解釋道。例如，這些是即將到來的“飛行汽車”行業的預期情景。“由于快速更換系統和較短的安裝時間，系統上的產品更換沒有問題且經濟上合理：在加速期間，FPP系統的容量可用于多個組件。隨著數量的增加，機器公園得到擴展，系統變得更加專注。優勢：流程保持不變 - 無需新產品開發，也無需重新認證零件。“
“由于FPP和AFP工藝都用于航空航天工業，FPP和AFP的層壓板規劃是否可以在我們的CAE軟件ARTIST STUDIO中結合使用的問題，自然而然地在開發過程中出現。明確的答案：是的，它可以是合并后，“Cevotec執行副總裁Neven Majic博士補充道。
因此，FPP專家目前正在通過AFP工藝中使用的無端纖維帶的層壓設計相關功能擴展ARTIST STUDIO。新模塊TAPE ARTIST與ARTIST STUDIO無縫集成，還將使用MOTION ARTIST進行機器數據生成和過程模擬。TAPE ARTIST還可以與PATCH ARTIST結合使用到一個聯合模塊，使工程師能夠設計基于AFP和FPP技術的集成層壓板。
原文如下： Cevotec expands application range by multi-material layup for sandwich structures
Fiber Patch Placement (FPP) has become the preferred technology for the automated production of complex fiber composite components. The additive manufacturing of components with suitably-sized patches is used especially in the aerospace and automotive industries, for medical devices and sports equipment. In close cooperation with leading manufacturers of components for the aerospace industry, Cevotec further develops the entire patch placement process according to the requirements of the industry.
Cevotec’s FPP specialists are particularly interested in complex sandwich components with their sophisticated material mix, such as adhesive films, glass fiber and carbon fiber layers. These different materials are used to improve the adhesion and processability of carbon fiber material with the often-used aluminum honeycomb sandwich cores.
"The SAMBA Multi production systems, which we are currently developing, enables the automated lay-up of this special multi-material mix in one single system," reports Felix Michl, Cevotec's CTO.
In addition to glass fiber fleeces, metal structures and wood cores, also honeycomb cores, solid foams and additional materials have already enjoyed load-adjusted fiber patch reinforcements. Depending on process requirements, this can be done in-line or parallel to line production to optimize cycle times.
SAMBA Multi has parallel feeding units for different materials that are processed in one production system and placed precisely on 3D sandwich cores or preforming tools. By mounting the FPP unit on a linear axis, the concept also enables the production of particularly long and wide components in aerospace applications. Adapted to specific component sizes, we also scaled the patch grippers to DIN-A5 and DIN-A4 size to meet the requirements of common aircraft components. An integrated gripper station enables the exchange of grippers during the process.
"The automated multi-material lay-up of complex sandwich components has an extremely positive effect on process times and thus the production volume," explains Thorsten Groene, Managing Director of Cevotec: "The fiber deposition with controlled pressure and heat enables skipping intermediate compactions and thus reduces process times significantly.” In addition, Groene continues, FPP sustainably reduces recurring production costs in many applications. "Material savings of 20% - 50% play a major role, of course, but automation with FPP often enables further optimization of the overall process.”
Another advantage of SAMBA Multi is the high scalability of the production process. "One and the same process works both for a few hundred and several thousand units per year," explains Michl. These are expected scenarios in the up-and-coming “flying car” industry, for example. " Thanks to the quick-change system and short set-up times, a product change on the system is no problem and economically reasonable: During ramp-up, an FPP system’s capacity can be used for several components. With increasing quantities, the machine park is expanded and the systems become more dedicated. The advantage: the process remains the same – no new product development and no re-qualification of parts are necessary."
"Since both FPP and AFP processes are used in the aerospace industry, the question whether laminate planning for FPP and AFP can be combined in our CAE software ARTIST STUDIO, naturally arose in the course of development. The clear answer: yes, it can be combined," adds Dr. Neven Majic, EVP at Cevotec.
Therefore, the FPP specialists are currently extending ARTIST STUDIO by the relevant features for laminate design with endless fiber tapes as used in AFP processes. Seamlessly integrated into ARTIST STUDIO, the new module TAPE ARTIST will also use MOTION ARTIST for machine data generation and process simulation. TAPE ARTIST can also be combined with PATCH ARTIST to one joint module, enabling engineers to design integrated laminates based on AFP and FPP technology.
