AUTOMATED PRODUCTION OF CARBON FIBER REINFORCED THERMOPLASTIC SINE WAVE BEAMS

Abstract

Advanced thermoplastic composites offer the possibility for fast molding and welding and have a great potential for efficient composite processing techniques in aerospace applications. The research at the Center for Lightweight-Production-Technology (ZLP) in Augsburg aims at automation of thermoplastic composite production utilizing a flexible robot work cell with integrated hot press. A sine wave beam designed as crash-absorber serves to demonstrate the overall process chain. The production process is described in detail from as cut piece to final part. It includes lay-up of tailored ply stacks by automated preforming. Organo sheets are then produced via vacuum consolidation. The handling of laminate stacks and organo sheets is performed with a special designed clamping frame that is able to strain the 2D preform and withstand the process temperatures. In the subsequent press forming process the 3D shaping takes place. Finally the parts are trimmed and resistance welded to the final assembly. With this paper DLR BT will give insight into current work in the field of processing of thermoplastic composites. The established part production process is screened for optimization potential.