Beitrag zur Qualitätssicherung beim in-situ Tape-Legen komplexer Laminate

• Contribution to quality assurance in in-situ tape laying of complex laminates

Buschhoff, Clemens; Brecher, Christian (Thesis advisor); Hopmann, Christian (Thesis advisor)

1. Auflage. - Aachen : Apprimus Verlag (2022)
Book, Dissertation / PhD Thesis

In: Ergebnisse aus der Produktionstechnik 9/2022
Page(s)/Article-Nr.: 1 Online-Ressource : Illustrationen, Diagramme

Dissertation, RWTH Aachen University, 2021

Abstract

Climate change and the resulting ambitious climate targets for reducing CO2 emissions pose a challenge to the transport sector in particular. In the use phase, mass has a decisive influence on a vehicle's energy requirements. Electromobility reinforces this trend, as battery weights have to be compensated and range maximized. Therefore, lightweight construction is a frequently demanded criterion in the development of new products. Here, fiber-reinforced composites enable lightweight components with high mechanical properties. The challenge here lies in an efficient manufacturing process. With in-situ tape laying, it is possible to lay down unidirectional fiber-reinforced thermoplastic tapes in a load- and weight-optimized manner and thus to manufacture components both generatively and automatically. Thermoplastic matrix systems are very promising in this respect. Tape laying can be combined with already mature technologies such as injection molding, among others. In order to increase the use of the technology, it is necessary to address the factors that influence quality. Factors that have received little attention so far are the properties of the tape to be processed. Fluctuating tape qualities and lateral curve paths result in defects in the form of fiber corrugations and flaws. This paper therefore investigates the tape laying of lateral curved paths. To this end, the factors influencing the quality of tape laying are first defined and examined to determine whether they can be influenced. On this basis, two approaches to quality assurance are developed. By modifying the tape before laying down curved paths, the laminate quality is improved for curved paths. In addition, in-process tape monitoring is used to inspect the incoming tape, allowing the tape lay-up process to be adjusted and controlled accordingly. Modules are being developed for both approaches, which can be integrated into existing production systems. Finally, it will be demonstrated that the developed modules can be used to realize curves with larger angles, tighter radii and wider tapes than before, as well as to continuously record characteristic tape properties.