007 FKV Applications 2 WS0708
Transcript of 007 FKV Applications 2 WS0708
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Kindervater FKV_2007_08_Applications Applications-2: 52
Anwendungen von FVW (Teil2)
Christof Kindervater
Vorlesung WS 2007/2008DLR Stuttgart, Institut für Bauweisen- und
Konstruktionsforschung
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Kindervater FKV_2007_08_Applications Applications-2: 53
Composite rotor blades of wind energy converters
Blade hub connection
with loops
DEBRA
• 2-piece rotor blades
• GFRP rovings and
fabrics in hand lay up
• rotor diameter 25 m
• Mass of one rotor:
320 kg
• performance: 100 kW
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Kindervater FKV_2007_08_Applications Applications-2: 54
Composite fan blades of DNW wind tunnel
CFRP blades
• high specific stiffness:> high eigen frequenzcies > high RPM
• long fatigue life of CFRP
• good contour quality of blades > high aerodynamic efficiency
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Kindervater FKV_2007_08_Applications Applications-2: 55
Composite applications in sporting goods
• composite replace metal and wood
• use of all kind of f ibre and matrixsystems (the newer the better due toprestige!)
• high vibration damping
• low weight combined with highmechanical performance
• not sensitive to moisture (comparedto wood!)
• high design flexibility and trimmingcapability (weight, stiffness etc.)
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Kindervater FKV_2007_08_Applications Applications-2: 56
Composite tennis rackets
2 frame design for vibration damping
• wet lamination with carbon braidings,
2-rac
• hand lay up mass production with
prepreg and heated steel moulds
(6-8 bar, 160°C, 3-10 min.)
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Kindervater FKV_2007_08_Applications Applications-2: 57
Composite bicycle frames
Hercules monocoque
• composite conform design without
metal fittings
• sandwich design with honeycomb core
• low weight (9,5 kg), high stiffness
• CFRP disc wheels
• high prestige
Composite bike frame
• tubes with hybrid braidings
(80%CFRP/20%GFRP)
• good riding comfort
• light weight, no corrosion
• price comparable with steel frames
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Kindervater FKV_2007_08_Applications Applications-2: 58
Composite Applications cont´d
Ship building• applications since 50 years
• 20 years of guarantee
• use of glass mats and fabrics and polyester resins (price!),
short construction times
• local reinforcements with CFRP and aramid
• monolithic and sandwich designs
• corrosion resistance (salt water)• GFRP submarines, non magnetic
• high performance racing yachts
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Kindervater FKV_2007_08_Applications Applications-2: 59
Composite ship building applications
Mine sweeper
Ship hull manufacturing
• hand lamination/resin infusion with polyester
resins (price!)
• sandwich design
• low weight, low cost, saltwater resistance
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Kindervater FKV_2007_08_Applications Applications-2: 60
Composite Applications cont´d
Vehicle technology
• wide application of composites• preferred use of low cost composites with glass fibre
reinforcements
• high tech applications of carbon fibres in racing cars (chassis
and crash cones)
• hand-lay-up, fibre spraying, pressing, filament winding, resininfusion and autoclave manufacturing technique
• low weight results in fuel savings and other synergetic effects
(small engine, single axle, small ti res etc.)
• good damping and corrosion resistance
• structural examples: large body parts, drive shafts, springsand torsion rods, bumper systems, chassis frames, train
coach structures and bumpers
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Kindervater FKV_2007_08_Applications Applications-2: 61
GFRP leaf spring for trucks
• series production for special
trucks (fire fighter vehicles)
• UD-prepreg with epoxy matrix• springs are cut from wide plates
into the proper width
• 60% weight saving
• better elastic energy storage dueto high strength and low E-
modulus of GFRP
• uncri tical damage progression
• high fatigue life
• good acoustic properties
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Kindervater FKV_2007_08_Applications Applications-2: 62
Fact 4 prototype of sport racing car:
• car body: CFRP and aramid sandwich
• very stiff design with IMS carbon fibres
• good cost relation for prototype
manufacturing
BMW Z1 floor structure:
• sandwich design with GFRP face
sheets > self supporting design• small number series production
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Kindervater FKV_2007_08_Applications Applications-2: 63
FKV im Automobilbau
Porsche Carrera GT:
• Gesamtstückzahl: 1500 (ca. 2 Jahre)• CFK-Prepreg (Handarbeit)
• Keine Crashperformance in der CFK-Struktur
BMW Z22:
• Gewichtsvorteil gesamt: 33%
• Kraftstoffersparnis: 45%
• Crashperformance entspricht 528iA
durch Al-Unterkonstruktion
Mercedes SLR McLaren:
• Front-/Heckstruktur, Fahrgast-zelle,Flügeltüren und Motorhaube ausCFK
• CFK- Front-Crahstruktur (CFK-Längsträger: 3,4 kg)
• Motorträger aus Al-Sandguss
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Kindervater FKV_2007_08_Applications Applications-2: 65
Composite racing sport applications
Racing car CFRP monocoque:
• low weight, high torsion
stiffness
• sandwich or integrally stiffened
• CFRP energy absorbers
Racing motor bike:
• CFRP and GFRP application more than 10
years
• manufacturing: pressing, filament winding, fibre
spraying, autoclave
• parts: cowlings, frames, wheels, springs
• GFRP parts for series production
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Kindervater FKV_2007_08_Applications Applications-2: 66
CFRP application in CLT DTM 2000
CLK 2000 CFRP front structure:
• spoiler and body parts
• venting system
• front crash box
Quelle: HWA
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Kindervater FKV_2007_08_Applications Applications-2: 67
Entwicklung der FKV-Crashboxenfür Mercedes-CLK bei DTM 2000
Vergleich von num. Simulation mit realem Crashtest
Partner/ Auf traggeber: HWA GmbH, Affalterbach
Nachweistest der vorderen Crashbox
v0=13 m/s, m=1200 kg
Simulation der vorderen
Crashbox
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Kindervater FKV_2007_08_Applications Applications-2: 68
Steering column crash absorber
Kevlar absorber element;
Serienelement in GFKSerienanwendung in 7er und 5er BMW-Lenkmodul
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Kindervater FKV_2007_08_Applications Applications-2: 69
Composite applications in vehicle and safety
technology
Sports car seat:
• very low weight
• resin injection manufacturing
Ballistic protection helmet:
• same weight as steel helmet provides50% higher protection
• low weight results in high wearing comfort
and low neck loading > less fatigue
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Kindervater FKV_2007_08_Applications Applications-2: 70
Neoplan Metroliner - a composite bus
• small series production (100 buses)
• vacuum assisted curing with CFRPand GFRP sandwich (50 mm and 40
mm foam cores)
• 40% weight saving > smaller engine
>lighter axles >lighter/less tires
>lower fuel
• less tire and brake tearing
• disadvantages:
- high noise level with prototypes
- 25% higher manufacturing cost
compared to conventional steel frame
design
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Kindervater FKV_2007_08_Applications Applications-2: 71
Neoplan Metroliner structural assemblage
Structural modules before
bonding assemblage
Steel fixtures for adhesive bonding ofMetroliner modules
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Kindervater FKV_2007_08_Applications Applications-2: 72
CFRP engine parts
• Mass reduction of oscillating
parts > higher performance
• CFRP rovings and fabrics
with epoxy Novolack matrix
CFRP part mass mass reduction
• bolt 107 g 60%
• piston rod 270 g 65%
• crank shaft 3010 g 50%
• valve rod 30%
• valve lever 53%
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Kindervater FKV_2007_08_Applications Applications-2: 73
Composite train applications
Train coach design conceptTrain coach manufacturing
• sandwich structure in tape windingtechnique
• integration of venting /electrical
system in foam core
• highly automated processQuelle: Schindler Waggon
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Kindervater FKV_2007_08_Applications Applications-2: 74
Series application since 1997
ICT crash absorber:
4 GFRP absorber (fabric/epoxy matrix)
4 Load: 750 kN, stroke: 300 mm
Crash sequence:
4 impact mass: 80 t
4 impact velocity: 4 m/s
AVI
ICT - Pufferabsorber
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Kindervater FKV_2007_08_Applications Applications-2: 75
Composite applications in civil engineering
GFRP pedestrian bridge:
• Length 120 m, main span: 63 m
• GFRP polyester resin
• pultrusion profiles are adhesive
bonded at construction site
CFRP and DYNEEMA cables:
• less weight compared to steel
• corrosion resistant and low maintenance cost
•more design flexibility with concrete structures,
higher possible span with bridges
• DYNEEMA cables do float
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Kindervater FKV_2007_08_Applications Applications-2: 76
Radio telescope La Silla (Chile) at 2400 m altitude
• frame work with CFRP tubes
• mirror surface with CFRP plateswith a tolerance of +/-45μm
• low thermal expansion
coefficient and high stiffness
> non -uniform sun radiation
> high wind speeds up to 200
km/h and 10 cm ice accretion
• no protection radome necessary
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Kindervater FKV_2007_08_Applications Applications-2: 77
Composite pioneer bridge
• metal structure with local
reinforcement with CFRP
profiles
• stiff and light design
> good handling
> no corrosion
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Kindervater FKV_2007_08_Applications Applications-2: 78
Composite Applications cont´d
Medicine technology
• price is not driving factor
• light weight and stiff structures
• primary use of carbon fibres
• long life cycles due to high fatigue performance• no corrosion
• X-ray transparency
• human body compatibility
• examples: arm and leg prothesis, orthesis, implants, medical
tools/equipment, x-ray tables
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Kindervater FKV_2007_08_Applications Applications-2: 79
Composite medicine technology applications (1)
Composite wheel chair:
• CFRP frame and plates
• resin injection with Injectex fabric
• mass: 6,5 kg
• price comparable with titanium
X-ray table:
• high stiffness for good positioningaccuracy
• x-ray transparency > low radiation
loading for the patient
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Kindervater FKV_2007_08_Applications Applications-2: 80
Composite medicine technology applications (2)
Stereotaxie apparatus:
• application for Kernspin tomography
• CFRP/epoxy ring provides highstiffness for good positioning accuracy
of instruments
• metal parts would not allow
diagnosis due to Eddy currencies
Artificial hip joint implants:
• good human body compatibility
• implant stiffness can be adapted tonatural bone properties
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Kindervater FKV_2007_08_Applications Applications-2: 81
Composite medicine technology applications (3)
CFRP leg prothesis:
• provides natural walking feeling
• light with good damping
Lower leg prothesis:
• GFRP leaf springs
• provides natural walking and spring
damping behaviour
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Kindervater FKV_2007_08_Applications Applications-2: 82
Composite Applications cont´d
Mechanical engineering, plants and facilit ies
• Low weight and mass inertia in highly accelerated and
decelerated parts
• high vibration strength and damping
• higher revolution speeds with rotating parts, shorter
machining costs• low maintenance
• simple and application oriented design
• good chemical resistance
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Kindervater FKV_2007_08_Applications Applications-2: 83
Composite robotics applications
GFRP robotic arm:
• filament winding with integration of metal
bearings > no later machining
• re-useable segmented winding mandrel• 65% weight reduction
> 13% higher max. acceleration
> 34% higher max. pay load
compared to metal design
CFRP manipulator arm (ROTEX
ground experiment):
• weight 212 g
• failure load 54 kg lever loading
• axle distance: 340 mm
• max torsion: 123 Nm
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Kindervater FKV_2007_08_Applications Applications-2: 84
Composite applications in weaving machines
Head of thread manipulator arm:
• CFRP leaf springs
• high fatigue life
• low mass in highly oscillating andaccelerated part > low transmission power
and faster machines
CFRP thread manipulator arm:
• CFRP thermoplastic matrix(PEEK)
• high vibration damping
• high accuracy positioning
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Kindervater FKV_2007_08_Applications Applications-2: 85
Composite applications in mechanical engineering
Grinding table of cog-wheel gr inding
machine:
• low weight and high stiffness reducesmachining time
• mass: 33 kg, metal cast: 100 kg
• Frequency: 3 Hz
CFRP machine drive shaft:
• filament wound with metal fittings
• almost zero thermal expansion
• higher dynamic strength combined
with less mass provides higher RPM
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Kindervater FKV_2007_08_Applications Applications-2: 86
Composite tank and vessel applications
GFRP loop fixture of low temperature gas tank
• low thermal conductivity and high strength
GFRP containers:
• filament wound with glass
and polyester resin
• chemical resistant• suited for wine and juices
etc.
Smoke gas cleaning
towers:
• filament wound GFRP
tubes with VE resin
• diameter up to 7 m
> on-site manufacturing
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Kindervater FKV_2007_08_Applications Applications-2: 87
Composite Applications cont´d
Electro technology/electronics
• electrical insulation with glass fibres laminates
• good acoustic sound quality and damping in hi-fi equipment
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Kindervater FKV_2007_08_Applications Applications-2: 88
Composite electric/electronic applications
GFRP plate for electronics:
•electrical insulation of GFRP
• glass fabric/epoxy resin
Electric cable
suspender:
• electr. insulation
and high strength• GFRP rovings
spiral wound
CFRP HIFI
equipment:
• good sound
quality
• good vibration
damping
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Kindervater FKV_2007_08_Applications Applications-2: 89
Composite Sousaphone
• low weight: 7,2 kg> can be carried and played
by kids and women
• damage tolerant GFRP
> no change of sound quality
• easy colouring and painting
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Kindervater FKV_2007_08_Applications Applications-2: 90
CFK-Violine
• Unempfindlich
gegenüber Witterungs-
einflüssen
• Exzellente Ansprache
• Große Dynamik
• AusgewogenesKlangbild
• Präzises und ausdruck-
starkes Spiel
Quelle: Diamo Violins