MAI ACoSaLUS – Research into automation techniques for the efficient production of composite sandwich components with specific automated fiberplacement processes
Optimization of fibreplacement processes for the production of sandwich components using digital tools to increase productivity and material efficiency in the aerospace industry.
Project Partners
GKN Aerospace Deutschland GmbH, SGL Technologies GmbH, Cevotec GmbH, Augsburg University of Applied Sciences
Duration
01.01.2021 – 31.12.2023
Funding authority
Bavarian Ministry of Economic Affairs, Regional Development and Energy
Motivation
The established process for the production of skin-layers for sandwich components is hand lay-up. The use of Automated Fibre Placement (AFP) represents therefore a fundamental innovation. Due to the technical challenges (press-in (denting, smashing, crushing) of the core, path design, bonding between skin-layer and core, etc.) a one-to-one transfer from AFP with conventional metal tools and slightly curved geometries is not possible. The project therefore aims to develop the production of skin-layers for sandwich components by 3D AFP into a robust process that can be used in large series. In this way, the MAI ACoSaLUS project contributes to increasing productivity and material efficiency in the aerospace industry.
Method
For the realization of this project, digital tools are used for the path design and the optimization of gaps/overlaps. In addition, TUM ensures the successful development of new semi-finished products (e.g. Towpreg) for aerospace applications by applying its process know-how as well as its testing capabilities for semi-finished products in the (uncured) processing state and making them available to the material manufacturer SGL iteratively for material development. With regard to online process monitoring, TUM's goal is to further develop the current system for use on complex sandwich components. Through innovative methods of image processing, the system is expected to be used for three-dimensional geometries reliably for the first time.
Acknowledgement
The Chair would like to thank the Bavarian Ministry of Economic Affairs, Regional Development and Energy for their funding of the project "Research into automation techniques for the efficient production of composite sandwich components with specific automatic fibre placement processes" (funding code: LABAY 113E).
