Preforming Cell based on single fibre manipulation

在斯图加特大学飞机设计研究所(IFB)，高性能纤维增强复合材料(FRC)领域的轻质结构和创新制造技术被研究、开发并转化为面向应用的原型。为此，并行创建了虚拟设计和计算方法，开发了资源高效和可持续的材料和产品制造流程，并借助认证的测试技术进行了验证。针对FRC轻量化施工模拟与制造技术的研究领域，IFB正在申请一种基于单纤维操纵的一体化预制室，以期为未来航空FRC结构开辟新的研究途径。基于单纤维操纵的一体化预成形单元旨在将不同的加工技术，即所谓的单纤维加工模块结合到一个可快速配置的、相互关联的、联网的、自我监控和传感器支持的生产环境中，用于实验室级别的FRC组件。在加工过程中对一个或多个定向增强纤维的定向和传感器监控的操纵和引导表征了单纤维操纵，以便产生载荷路径顺应性和近净形状部件的具体可调整的纤维结构。增强纤维应能够以粗纱、纱线、涂布和粘合带的形式进行加工(包括薄层)和丝束预浸料，以探索未来用于高性能应用的半成品纤维产品。对于扁平、平面和近净形状预制件的生产，将使用附加的单纤维铺设工艺，除了弯曲的、轮廓跟随的纤维路径外，还可以产生直的、单向的路径。在另一个处理模块中，将在编织过程中使用新的线轴载体技术来创建三维中空纤维结构。在径向编织过程中，可自由配置的单个纤维操纵将通过首次使用电子线轴单元来实现，该单元将在研究所自己的前期工作的基础上为该单元开发。因此，可以在工艺中可变调整的纱线力将导致完全新的与负荷相适应的纤维体系结构，以及当前工艺窗口的显著变化。由于编织过程中纱线力的变化，以及定向进料和回缩的可能性，因此也可以处理以前无法编织的部件几何形状。作为软件定义的制造方法的基础，工厂模块将通过物联网平台进行数字链接。持续的过程数据采集、存储和并行评估为未来数字支持的产品和过程开发研究提供了以前不可用的基础。

At the Institute for Aircraft Design (IFB) at the University of Stuttgart, lightweight structures and innovative manufacturing techniques in the field of high-performance fibre-reinforced composites (FRC) are researched, developed and transferred into application-oriented prototypes. For this purpose, virtual design and calculation methods are created in parallel, resource-efficient and sustainable material and product manufacturing processes are developed and validated with the help of certified testing techniques. For the research area of lightweight construction simulation and manufacturing technology of FRC, the IFB is applying for an integrative preforming cell based on single fibre manipulation in order to open up new research approaches for FRC structures in aviation in future. The integrative preforming cell based on single fibre manipulation aims to combine different processing techniques, so-called processing modules of single fibres into a rapidly configurable, interlinked, networked, self-monitoring and sensor-supported production environment for components made of FRC at laboratory level. The targeted and sensor-monitored manipulation and guidance of one or more directed reinforcement fibres during processing characterises the single-fibre manipulation in order to generate specifically adjustable fibre architectures of the load-path-compliant and near-net-shape parts. The reinforcement fibres should be able to be processed in the form of rovings, yarns, spread and bindered tapes (incl. thin-ply) and tow-pregs in order to explore future semi-finished fibre products for high-performance applications. For the production of flat, planar and near-net-shape preforms, additive single-fibre laying processes will be used, which, in addition to curved, contour-following fibre paths, can also produce straight, unidirectional paths. In another processing module, three-dimensional hollow fibre architectures are to be created using a new bobbin carrier technology in the braiding process. The freely configurable individual fibre manipulation in the radial braiding process is to be achieved through the first-time use of electronic bobbin units, which are to be developed for this cell on the basis of the institute's own preliminary work. The yarn force that can thus be variably adjusted in the process will lead to completely new load-appropriate fibre architectures in addition to a significant shift in the current process windows. Due to the variable yarn force during braiding as well as the possibility of a targeted material feed and retraction, it is thus also possible to process component geometries that were previously impossible to braid. As the basis for a software-defined manufacturing approach, the plant modules are to be digitally linked via an IoT platform. Continuous process data acquisition, storage and parallel evaluation provide a previously unavailable basis for research into future digitally supported product and process developments.