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24th Month Meeting WP4 Presentation

24th Month Meeting WP4 Presentation. Benoit LAURENT Federal-Mogul Systems Protection. Agenda. Brief overview of WP Background Structure and progress update WP4 Highlights during M18-M24 Selected exploitable results WP4 Future Planning Discussion Points.

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24th Month Meeting WP4 Presentation

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  1. www.3D-LightTrans.com 24th Month MeetingWP4 Presentation Benoit LAURENT Federal-Mogul Systems Protection

  2. Agenda • Brief overview of WP • Background • Structure and progress update • WP4 Highlights during M18-M24 • Selected exploitable results • WP4 Future Planning • Discussion Points

  3. WP4 – Manufacturing processes of 3D TRP final compound Research partners • 1 – AIT • 6 – Ugent • 8 – TUD • 9 – Leitat Industrial partners • 3 – CRF • 4 – Coatema • 5 – FMSP • 15 – Bentley • 17 – Promaut Work Package objective • WP4 develops the models, technologies and process adaptations to implement the final part draping and thermoforming. This WP is closely linked to WP3, developing former industrial steps, and overseen by WP2.

  4. WP4: Structure and progress update Tasks: • Task 4.1: Final production of the TRTC component 50% • Task 4.2: Product finishing processes and assembly of module components 20% Deliverables: • D4.10: Supervisedfixated preforms process M42 – Not complete • D4.11: Readymadetechnologies M42 – Not complete

  5. WP 4 Highlights M18 – M24Task 4.1a Draping • In coordination with TUD simulations: draping tests over a 450mm hemisphere. • Manual tests simulating an automatic operation using a “push and hold” sequence. • Two hands at a time for draping. • Needles for fixing fabric around the base of the part. • Need for the usage of more or wider robot fingers for reducing space between them and prevent the wrinkling. • Design and building of passive grippers for robotic draping • The Fingers: for holding, dragging and pushing the fabric. • The Jellyfish: for brushing along the surface.

  6. WP 4 Highlights M18 – M24Task 4.1a Draping • Following the same draping strategies previously tried. • Tests carried out with a two arms Motoman robot. • Need for increasing the number of “tentacles” and raise their rigidity. • Introduction of active elements into the gripper or the tool. • Manipulation means studied in collaboration with PROMAUT, in case long displacements tasks are required during draping. • Vacuum: no affectation of A-class surfaces, high consumption, overcome porosity. • Needles: hinder surface finish, low consumption, poor holding force.

  7. WP 4 Highlights M18 – M24Task 4.1b Fixation • There is a significant melting of the PET-fibers after exposition to 6-9 flashes at a frequency of 2 flashes / s. • The result looks very similar to earlier trials with PP-fibers. • So the combination Glass/PET should be fixable in the same way as Glass/PP. The PET fibers should be black, mixed with white or colorless glass fibers.

  8. WP 4 Highlights M18 – M24Task 4.1d Thermopressing • 2nd Process campaign – Flat mold • Glassfibre 3D-Architecture + PP-Matrix

  9. WP 4 Highlights M18 – M24Task 4.1d Thermopressing • Design • Complex 3D-Geometry (Butter dish) • Manufacture • Heated top/bottomtools • Interim process campaign • Pure PET-Plate • Material issue • PP/PET • processinvestigations on plate @ 220 C° • initial U-Profile manufacture • PET • processinvestigations on plate @ 270 C°

  10. WP 4 Highlights M18 – M24Task 4.2 Productfinishing, assembly • Metal - GFRP • Mold design • Mold manufacture Top stamp Bottom Die

  11. WP 4 Highlights M18 – M24Task 4.2 Class A Finish • Involved parameters • Substrate quality • Paint materials • Process parameters • Testing requirement established • Important characteristics • Secondary characteristics • Processes: • Formed film (GE plastic/Azdel Inc ) • Paint Coating • Literature review • Amorphous substrates have higher gloss than semicrystallinematrices • Matrix-rich layer improves gloss • Adding nano-particles (e.g. CaCO3) can enhance gloss • Patent review • Resin rich surface layer (powder or film) • Polished mould • Metal sheet on composite

  12. Selected WP exploitableresults

  13. WP3 WP1 WP Future planning 1.1 1.2 1.3 1.4 3.1 WP2 • WP4 meeting: 2013 March 15th in Crepy, France • Milestone 10: Fixation Process (M30 - Coatema) • Process for on-line/off-line fixation of high draped multilayer textiles available and functional • WP4 / WP6 Interractions 2.1 2.2a 2.2b 2.2c 2.3 3.2a 3.2c WP4 4.1a 4.1b 4.1d 4.2 3.2c WP5 4.1c 5.2 5.3 WP6 6.1 6.2 6.3 6.4

  14. WP Future planning

  15. WP Future planning

  16. WP 4 Discussionpoints • WP4 March meeting agenda discussion: • Draping • Missing input and status • 3D textile draping • Gripping strategy • Fixation • Strategy for fixing draped part • Thermoforming • Lessons learned • PET process parameters acquisition • 3D textile thermoforming strategy • Finishing • Sub-part assembly • Part integration • Class A finish • Model and simulation process parameters (D2.6)

  17. Questions? Thankyouforyourattention!

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