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MoVeTech - Model-Based Processing Technique for the Manufacturing of High-Quality Structural FRP Components for the Aerospace Industry

It is within the MoVeTech project that the concept of model-based processing technology was first implemented in the ARTM (Advanced Resin Transfer Moulding) process. This concept is based on the idea of combining phenomenologically based know-how about relevant mechanisms (heat conduction and transfer on moulds and composites, flow processes during mould filling or curing kinetics of reactive resins) in the form of mathematical models, and making them available at the level of process management - while adhering to real-time requirements.

Short Description

Motivation

Fibre-reinforced polymer composites (FRP) are being used more frequently for structural components. As a result, increasing demands are being placed on FRP processing techniques with regard to the mass production of components with high mechanical properties. The prepregs conventionally used in aviation, which are deposited manually or automatically and cured after the entire component structure has been built up in an autoclave process, have significant disadvantages here, in particular due to autoclave curing. 

High fibre compaction and long flow paths during the preform impregnation in the RTM process are the cause of insufficient impregnation and high pore contents in the finished FRP component. The ARTM process avoids these issues and is a promising method for manufacturing high quality FRP components for high volume applications.

Objectives

  • Implementation of the concept of a model-based processing technique for manufacturing of high-quality structural FRP components.
  • Fully automated component production by coupling instrumented tools with intelligent system technology based on cyber-physical systems.
  • Verifying the suitability of this concept using the example of a given aircraft component.

Content

With regard to the current state of the art, there is no known approach that can reliably and automatically take into account or even actively integrate into the process management the large number of variable process parameters in FRP processing. These circumstances contribute to the fact that today the mass production of FRP components has comparatively high reject rates. Indeed, there is a need for optimisation, both from a technical and economic point of view, and especially against the background of increasingly high demands on process reliability, dimensional accuracy and surface quality.

Methodology

It is within the MoVeTech project that the concept of model-based processing technology was first implemented in the ARTM process, and its suitability for exploiting hitherto unused technical and economic potential was investigated.

For this purpose, the models that are to be used have to first be selected and parameterised. In addition, approaches for an efficient analytical or numerical solution for these models have to be developed. Finally, these implementations are to be made accessible to the process management via suitable hardware components as well as hardware and software interfaces, with particular attention being paid here to compliance with real-time requirements.

Outcome

In an ongoing process, the models now available at the process management level are continuously fed with data that is recorded via sensors on the processing machine, the moulding tool or directly in the composite material. That is how it is possible, on the one hand, to continuously monitor the processing machine itself and the materials that are being processed, as well as, on the other hand, to actively intervene in the process control in order to permanently set optimum processing conditions.

Project Partners

Funding program: TAKE OFF