Neil Reynolds, WMG University of Warwick, Innovations in Composite Materials Processing
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Transcript of Neil Reynolds, WMG University of Warwick, Innovations in Composite Materials Processing
Shaping the Future
Innovations in CompositeMaterials Processing
Neil Reynolds
Automotive Composites ResearchCentre, WMG
Polymer Innovation Network21st October 2015
2
Agenda
Background
Introduction to WMG ACRC research
Key capabilities
3
Background
Aims:– Development and application of suitable materials,
processing and simulation technologies for high-volumestructural application of composites in automotive industry
Considerations:– Cost (raw materials & utilisation)
– Cost (investment in processing technologies)
– Cost (cycle time)
– Also – LCA/recyclability, integration (joining)
Approach:– Industry-led collaborative R&D using a combination of
traditional and industrially-relevant research tools Fundamental analytical techniques through to industrial process
demonstration
4
Structural Composites at WMG ACRC
Processing:– Pre-preg compression moulding (PCM)– CF-SMC– Rapid stamp-forming of aligned fibre thermoplastics– HP-RTM & compression RTM, in-situ polymerisation– Formability/drape– Automation
Joining:– Volume-ready joining techniques– Pre-treatments– Automation
Performance:– Stiffness/strength & crash energy management– Durability/fatigue– Provision of key data for performance simulations, enabling
component design
5
WMG ACRC Processing Capabilities
Engel v-Duo 1700– Multi-functional 1,700t press– 2.2 x 1.8m usable platen area– Fully instrumented (pressure, temp, cure)– Sliding lower table
Heating/transfer station on order
Hennecke Streamline HP-RTM– 3+1 (Resin/Polyol)/Hardener/Isocyanate + release
agent– 60 litre day tank capacity (x3)
Zund CNC Cutting Table 2-D Ply Assembly
– Picking, assembling, joining– Up to 8 different layers/plies can be stored– 4-axis robot used to pick and place individual
layers/plies
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WMG Test/Analysis Capabilities
ACRC:– ±250kN static Instron, temperature chamber, video
extensometry
– Mettler-Toledo HP-DSC
– Zeiss auto stage optical microscope
WMG:– 12kJ instrumented drop tower
– VHS Instron (up to 25m/s)
– 3x fatigue frames (up to ±250kN)
– ±100kN static Instron
– SEM, DMTA, CT scanning
7
Thanks for Listening
Neil Reynolds
Senior Research Fellow
Automotive Composites Research Centre, WMG
www.wmg.warwick.ac.uk
02476 524787