Composite materials are often the key to lightweight design for many applications. However, these hybrid materials face a major challenge where recycling is concerned.

The experimental components were manufactured in a fully automated SMC manufacturing cell, developed by Engel, with an Engel v-duo 700 machine and an easix KR35 articulated robot

A Research Project Highlights the Recycling Potential of Lightweight Composites

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Kohlenstofffasern / -matten

Kunststoff Werkstoffe

Verstärkungsstoffe

Anlagen zur Composite-Herstellung

Kunststoffverarbeitung: Maschinen und Komponenten

Spritzprägen

Kunststoffverarbeitung: Verfahren

Spritzgießen

Bruchmechanische Prüfung

Messtechnik

Werkstoffprüfung

Verbundwerkstoffe / Werkstoffverbunde

Harzsysteme für Composite-Herstellung

UD-Tapes

Presswerkzeuge, Kunststoff

Werkzeuge für die Kunststoffverarbeitung

Pressen von Kunststoffen

Faserverbundwerkstoffe

Andere Werkstoffe

Kunststoff-Recycling

Kunststoff-Aufbereitung

Qualitätssicherung Kunststoff

Qualitätssicherung

Zero-Waste Concept for Carbon SMC

The toolmaker Siebenwurst uses injection molding simulation to optimize part design and production processes in its routine workflows. Among other things, Simcon’s software ensures the quality and dimensional accuracy of the plastic frame for the first series-produced injection molded e-bike.

The frames give the e-bikes an extraordinary design, with robustness comparable to steel or aluminum

Controlling Complex Development and Manufacturing Processes, Using Simulation

Spritzgießwerkzeuge

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Spritzgießsimulation

Software

Simulation

A Bike Frame from an Injection  Molding Machine

Climate change and the transport revolution are demanding smart fiber-reinforced composite solutions. In sectors such as the marine industry, infrastructure, and rail vehicle construction, many different fire protection concepts are competing. The composites industry is paying increased attention to recycling.

The first natural fiber-reinforced satellite panel permits safe space exploration and completely burns up on re-entry into the earth’s atmosphere

16:9

20:7

Fiber-Reinforced Composites Drive Innovation in the Transport and Construction Sectors

Glasfasern / -matten

Sekundärfasern

Kunststoff-Rezyklat

Fasern

Faserverarbeitung

Composites Are Trendsetters in Lightweight Design

Continuous fiber-reinforced thermoplastic composites have also become established with thin-walled housings for consumer electronics and information technology. Not only do they offer high stiffness and help to reduce weight, but also enable the integration of classy appearance and functions. What is more, if the housings are produced using the hybrid molding process, costs, processing steps, and cycle times can be reduced.

The Carbon 1 Mark II smartphone from Carbon Mobile was developed in Germany. The matt-black carbon fibers lend the smartphone a classy high-tech look

Composites Reduce Weight and Simplify Production of Electronics Housings

Kunststoff

Bauwesen

Baustoffe

Kunststofffasern

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Lightweight to Fit in a Pocket

As a result of the Corona crisis, press manufacturer Wickert sees only a temporary slowdown in the growth forecasts for composite technologies. The company currently sees four trends in system engineering.

Composite press for research: for scientists at the Chemnitz University of Technology, Wickert developed a highly flexible four-column upper piston press which offers a high level of freedom and diversity in application

The Demand for Composites Will Keep Growing in the Future

Pressen

Maschinen für die spanlose Fertigung

Duroplaste

Automatisierungstechnik

Hochleistungskunststoffe

Thermoplaste

Naturmaterialien

Trends in Composite Manufacturing

Thanks to a combination of polylactic acid and flax fabrics, Lanxess launches a full biocomposite in the Tepex range of continuous fiber-reinforced thermoplastic composites.

Demonstrator component with polylactic acid matrix and fabric reinforcement based on flax fibers. The component surface features a brownish bio-carbon appearance, which originates from the flax fibers

Biological and Suitable for Many Applications

As the long-awaited event of the global composites community, JEC World 2022 in May will bring together professionals from all backgrounds, eager to meet again in person.

JEC World 2022 in May will bring together professionals from all backgrounds, eager to meet again in person

The Global Composites Community Reunites in Paris

Tapes must be stacked both with high accuracy and efficiency. In the ongoing development of its tape-stacking cell, Engel places a third focus on simplifying operation. CAD-based tape stacking, which Engel has implemented in a customer’s system for the first time, will play a role here. Further new features are the pyrolysis function for cleaning the welding elements, as well as the modular end-of-arm tooling for handling the semi-finished products.

The new modular end-of-arm tooling of the tape stacking cell increases both the cost effectiveness and the flexibility. The functional elements can be individually positioned thanks to a perforated grid.

CAD-Based Tape -Stacking

Bildverarbeitungssysteme

Fertigungsautomation

Bildverarbeitung

Industrieroboter

Montagetechnik

Greifer für die Kunststofftechnik

Handling, Handhabungstechnik

Precise but Highly Efficient

JEC World 2022 will take place from May 03 to 05 in Paris Nord Villepinte with an interesting conference program.

The conferences program will be available for free to all registered participants, in two Agoras (Hall 5 and Hall 6) and also online via JEC World Connect.

Conferences Program

The battery system is one of the heaviest components in the powertrain of an electric vehicle. The use of lightweight materials and high-volume production processes according to requirements and functionality offers significant potential to reduce weight without compromising on safety or performance. A new technology concept shows the particular advantages of using a modified direct process with a tailored material selection.

Lightweight battery module with lithium-ion battery cells in pouch cell format and SMC module end plates.

Lightweight Traction Battery System for Electromobility

Elektromobilität

Mobilität

Leichtbau

Polyurethan

Energiespeichersysteme

Lightweight Construction  for Heavyweights

Particularly two industries have shown considerable interest in FPP technology: aerospace industry in automating the lay-up processes of multi-material lightweight components with sandwich cores, as well as manufacturers of CFRP pressure vessels for hydrogen-powered vehicles (FCEVs), who can thus achieve savings in the double-digit percentage range. In both areas, FPP is the first technology to automate critical fiber lay-up processes in order to industrialize the production.

Laminate reinforcement of filament-wound pressure tanks. The shape of the patches and the gripper is adapted to the size and complexity  of the component.

New Applications for the Automated Production of Fiber Composite Components

Greifer

Inspektionssysteme

Reinforcement on Approach

Röchling is taking over the Swiss SMC specialist Compotech, thereby expanding its product portfolio with large-format compression molded parts.

The integration also secures the continued existence of the Compotech site in Switzerland for the employees in the long term.

Röchling Takes Over Compotech

A new type of injection moulding press for the first time combines the processing options of a pressing machine, melt-strand deposition-unit and injection units for multi-component and MuCell technology. The many different possibilities offered by this machine are aimed particularly at efficient production of functionally integrated, flat, lightweight components by low-flow film or textile in-mould lamination, microcellular foaming technology and hybrid technology. 

Process combinations: Intelligent Machine Technology for Flat, Lightweight Components 

A new CFRP technology has the potential to be used for the first time in volume production in the automotive industry for the manufacture of lightweight parts of carbon fibre-reinforced plastics. 

Automotive Industry: Innovative CFRP Technology for Volume Production 

On over 30 presses, the Aircabin GmbH moulds a great variety of fibreglass components for the interior furnishings of the Airbus fleet. For increased transparency, reliability and efficiency down the entire production line, a central PC-based HMI system has been in use for about one year. 

Logistiksysteme Software

Kunststoffhandel

Production Control: Press Process Transparency 

Pressing of Ballistic Panels Made of Fiber-Reinforced Plastics

Demand for fiber composite panels to protect military vehicles, armored limousines, ships and helicopters is steadily on the rise. For over four decades, they have been manufactured on Wickert composite presses. The most recent contract: a line for a German defense company that went into operation in late 2021. The project demonstrates what is being demanded of press technology.

Temperature tolerence, force density, pressure setting: requirements for press technology

The very first armor made of fiber composites dates back to ancient times. At that time, several layers of linen were joined with glue to form a stiff fabric laminate that warriors wrapped around their bodies. It is said that Alexander the Great protected himself with what was referred to as a linothorax.

Today, alongside bullet-proof personal vests, lightweight ballistic panels are in particular demand for protecting vehicles, ships and aircraft. They are made from high-performance materials such as aramids and high-performance polyethylenes, for example. Combined with glass, ceramic and metal fibers made of aluminum oxide, silicon carbide, boron carbide, aluminum and armor steel, they are heated in automated systems and compressed under pressure to form fiber composite panels.

Specialty companies produce the ballistic panels customized for specific applications. Such applications include sensitive areas on warships, container ships and military trucks, plus the bodies of luxury limousines and the outer shells of helicopters. The liners are designed to provide protection against bullets, explosives, fragments and missiles, yet at the same time be very lightweight.

A Niche Market Experiencing  Steady Growth

Growing weapon systems, an increase in terrorist threats since September 11, 2001, and the threat of piracy to civilian merchant shipping are all driving demand. “Wickert has been manufacturing composite presses to produce ballistic panels since the 1980s. For a long time this was a niche market that featured a relatively consistent contract volume. However, the market has picked up noticeably in recent years and has continued to grow ever since,” explains Stefan Herzinger, managing partner of Wickert Maschinenbau.

Just one current example: in September 2020, Wickert delivered a WKP 52000 composite press to a German defense company. The heart of the contract, which was executed as a turnkey project, is a Wickert standard press modified to produce ballistic panels.

Weighing 150 t, the press features a sub-piston frame design with a full hydraulic closing system that boasts a press force of 52,000 kN and 1600 x 2500 mm heating plates. Also included in the contract was a fully automated parts loading and unloading system and a heating/cooling system with thermal oil.

The hydraulic composite press was designed and manufactured at the company’s headquarters in Landau in Germany. Here is where Wickert has always manufactured the equipment according to the customer’s specific requirements. Processing temperatures of up to 500 °C and press forces of between 20 and 100,000 kN are possible, as are plane parallelism of up to 0.025 mm/m. The dimensions of the presses and their precision heating plates are freely selectable. Multiple options for automation and networking, and the integration of other manufacturing processes such as RIM and RTM injection, ensure high productivity and a broad range of applications.

Ballistic panels are manufactured with the ultimate goal of producing products offering a consistently high level of protection. To achieve this, the system technology must meet three requirements in particular:

<ul><li>The blanks and semi-finished products must be heated and cooled as consistently as possible.</li><li> The pressure during pressing should be as equal as possible at all points of the entire panel.</li><li>The system must close precisely. This requires the highest possible plane parallelism.</li></ul>

Temperature Tolerance of Only ±3 °C across the Entire Panel

To achieve homogeneous temperature distribution, the panel uses heating/cooling plates with a total heating capacity of 360 kW, drilled from the blank and designed for long service life. This tempering process is costly, but “Wickert guarantees a very homogeneous temperature distribution with a tolerance of ±3 °C over the entire panel,” emphasizes the managing director.

The WKP 52000 stands out due to its very high force density. Six press cylinders made of high-strength steel generate the pressing force and apply it evenly to the product. Stefan Herzinger explains that fitting cylinders with the required output into the compact press in a very confined space was a challenge. “In the end, we succeeded. We have made optimum use of the available space, and now not even a sheet of paper will fit in there.”

To ensure that the force distribution can be controlled as precisely as possible, Wickert has also included a fine pressure setting of a mere 960 kN. “Normally, the minimum press force is 10 % of the maximum output, meaning that in this case it would be 5200 kN,” explains Herzinger.

The clamping system is fully hydraulic and is equipped with an additional suction process. Consequently, it not only moves extremely fast at 40 mm/s, but can also be controlled with extreme sensitivity.

The main piston is sealed by a redundant system that reliably keeps it from leaking. The hydraulic system is driven by an axial piston high-pressure pump, allowing power and speed to be freely preselected for all driving functions. This ensures that the hydraulic system works quickly, sensitively, reliably, and precisely, and that the output can be reproduced accurately at any time.

The press accuracy contributes significantly to the quality of the production process. “Using high-quality standard components from a coordinated modular system and our expertise in integrating peripheral components are important prerequisites,” Herzinger adds. Not to mention more than 120 years of experience in press and plant engineering.

The delivered press also scores points in the press run with a plane parallelism of 0.5 mm/m, so that the upper and lower dies close exactly.

The blanks, which are manually prepared from up to 60 layers of fibers impregnated with a special plastic, are automatically loaded into the press using loading baskets. The tempering system heats them up in the die first to 40 °C and then, in a second step, to 160 °C. This causes the plastic to melt; and the blank is pressed under pressure into the desired shape. The semi-finished product then cools down again in the mold to 40 °C. Then it is automatically removed and cooled down to room temperature.

This cycle takes between one and two hours. The 1600 x 2500 mm ballistic panels then only need to be cut to the required size.

Originally, the press was delivered for pressing one panel at a time. “For a relatively low added cost, there are also versions with up to seven levels. This allows seven times the number of pieces to be produced in a single cycle,” explains Herzinger.

Sensors are used to record all process data for quality assurance and detailed documentation of the manufacturing process. There are three sensors integrated in the product itself, providing information on the temperature of the panels during processing. The entire system is controlled centrally with the aid of an intuitive “Press Easy” control system. A VPN also enables remote access, which is used for remote maintenance as well. The entire system is safeguarded by a security fence, monitored doors, light barriers and scanners. Moreover, it also features a mold safety system with four-way measurement to prevent misalignment.

Wickert Maschinenbau GmbH  

https://www.wickert-presstech.de

Ausgabenartikel

Ballistic panels are being used as armor for civilian and military vehicles, ships and aircraft. The image shows a test blast to demonstrate the safety for vehicle occupants.

Stefan Herzinger, managing partner at Wickert: “Precise force distribution requires sensitive pressure adjustment.”

The composite press that was delivered to a German defense contractor is a smaller model of the WPK 60000 shown with automated loading and unloading.

View inside an automated composite press: generally, the systems are customized for each customer specifically. Process solutions that can be integrated include infrared heating systems, transport and robot systems, plus intelligent networking with higher-level control systems.

Hauptartikel Wickert

Composites-Presses for Ballistic Panels 

 F. Stephan Auch is a freelance journalist and the owner of auchkomm Unternehmenskommunikation.

<a href="http://www.wickert-presstech.de/en/" target="_blank">www.wickert-presstech.de/en</a>

Read the German version of the  article in our magazine <i>Kunststoffe</i> or at <a href="https://www.kunststoffe.de/a/fachartikel/sicher-ist-sicher-3282468" target="_blank">www.kunststoffe.de</a>