DE102006038666A1 - Production method of workpiece made of fiber-composite material used in load bearing structure for aircraft, involves removing support and secondary material formed on upper surface of workpiece blank to form workpiece - Google Patents

Abstract

The method involves fitting a main material (6) made of pre-impregnated fiber semi-finished product e.g. carbon fiber and a secondary material (7) made of glass fiber to a support (3) for forming blank-mold areas (1,10) comprising main material and secondary material. The pressure is applied to the blank-mold areas to form a workpiece blank (14) such that the support is formed on the upper surface of the workpiece blank. The support and the secondary material are removed from the workpiece blank to form a workpiece. Independent claims are included for the following: (1) workpiece production apparatus; (2) method for producing plastic fiber-composite component; and (3) semi-finished product.

Description

The The present invention relates to a method of manufacturing a workpiece from a Fiber composite material and a corresponding device, in particular the production process according to the invention To run can.

Even though the present invention with reference to a problem in Related to the production of supporting structures of an aircraft is described, the present invention is not limited thereto, but relates generally to the manufacture of workpieces made of fiber composite materials, especially elongated Workpieces.

at The manufacture of an aircraft has fiber composites proven due to their high tensile strength at low weight. Next flat Be like elements in the outer shell also oblong Elements, such as e.g. the so-called stringers, made of fiber composites shaped. By means of a continuous process stringer can be used with a constant Profile cross-section can be made.

In An airplane becomes stringer with different cross sections needed. This requires the provision of various tools to to enable the variety of differently shaped stringers. Furthermore, stringers are needed their profile is along the length the stringer changes. So far stringer with constant profile cross section are handmade by placing additional Layers of composite material adapted by hand. The quality of such produced Stringer is of average quality and the process is elaborate.

A The object of the present invention is a production process and to provide a device with which workpieces a fiber composite material can be produced, the various profile cross-sections can have and preferably be produced with a single tool. Preferably the production takes place in a continuous production process.

• (a) Bereitstellen mindestens eines Trägermittels;
• (b) Aufbringen eines Hilfsmaterials und/oder eines Hauptmaterials aus einem vorgetränkten Faserhalbzeug auf das mindestens eine Trägermittel zum Bilden mindestens zweier Vorformbereiche derart, dass mindestens einer der Vorformbereiche das Hauptmaterial und mindestens einer der Vorformbereiche das Hilfsmaterial aufweist;
• (c) Verpressen der mindestens zwei Vorformbereiche miteinander zu einem Werkstückrohling derart, dass das mindestens eine Trägermittel an einer Oberfläche des Werkstückrohlings vorgesehen ist; und
• (d) Entfernen des mindestens einen Trägermittels und des Hilfsmaterials aus dem Werkstückrohling zum Bilden des Werkstücks.

The production method according to the invention according to claim 1 provides for the following steps:

• (a) providing at least one carrier;
• (b) applying an auxiliary material and / or a main material from a pre-impregnated semi-finished fiber to the at least one support means for forming at least two preform regions such that at least one of the preform regions comprises the main material and at least one of the preform regions comprises the auxiliary material;
• (C) pressing the at least two preform regions together to a workpiece blank such that the at least one carrier means is provided on a surface of the workpiece blank; and
• (d) removing the at least one carrier and the auxiliary material from the workpiece blank to form the workpiece.

The workpiece is formed by the manufacturing process of the main material.

The inventive manufacturing method fits the cross section of the workpiece by the auxiliary material to the cross section of a tool. The workpiece blank preferably has his entire length a constant cross-section defined by the tool is.

The Auxiliary material is preferably selected to be similar has mechanical properties such as the pre-soaked semi-finished fiber product, at least under the prevailing conditions of compression of the preforms, i. at the appropriate pressure and the corresponding Temperature.

The at least two preform regions may be arranged integrally on a preform be. The preform may then be folded or slit longitudinally for compression become. Each preform area can also be customized Preform can be arranged, i. each preform area corresponds exactly a preform.

According to one Continuing education will be in a third area of the vehicle several layers of the pre-soaked Fiber composite material and / or applied to the auxiliary material such, that no layer of the main material by a layer of the auxiliary material is covered. This will ensure that the auxiliary material along the surface of the produced workpiece blank is arranged and then completely removed the auxiliary material can be. Furthermore, can be in this way any thickness or strong areas in the workpiece from the main material.

A Embodiment provides that the main material and / or the auxiliary material is applied with a respective thickness, so that the thickness of the Vorformbereiche is homogeneous.

The pre-soaked semi-finished fiber product may comprise a woven fabric, a knitted fabric and / or a scrim. For this purpose, the semifinished fiber product preferably has fibers which are oriented perpendicular to one another. According to a development, the scrim is formed from an even number of layers, in their odd-numbered layers, first fibers into a first Direction and in the even-numbered layers, second fibers are aligned in a second direction and the first direction is inclined between 30 ° and 60 ° to the second direction. The first direction of all the odd-numbered layers is the same, and the second direction in the immediately consecutive odd-numbered layers is mirror-symmetric with respect to the first direction.

The carrier can be a slide.

The prepreg Semi-finished fiber preferably has carbon fibers.

The Auxiliary material may comprise a half-tool with glass fibers.

According to one Embodiment is one of the first of the preforms before pressing arranged parallel to a second of the preforms and then this two preforms pressed together.

A Continuing provides that the first preforming area and the second Preform can be pressed according to a curved curve.

According to one Embodiment is the first preform region with a first length and the second preform region is made with a second length, wherein the first length a length corresponds to the first Preformbereich after pressing and the second length a length of the second preforming area after pressing corresponds. In the curved Curve thus differ the first length and the second length. hereby a stress-free production of the workpiece is achieved. Especially a compression of fibers of the semi-finished fiber is avoided.

• – einer Zuführeinrichtung zum Bereitstellen mindestens eines Trägermittels,
• – einer Auflegeeinrichtung zum Aufbringen eines Hauptmaterials aus einem vorgetränkten Faserhalbzeug auf mindestens einem ersten Bereich des mindestens einen Trägermittels und zum Aufbringen eines Hilfsmaterials auf mindestens einem zweiten Bereich der Trägermittel zum Ausbilden mindestens zweier Vorformbereiche;
• – einer Formpresse zum Verpressen der zwei Vorformbereiche zu einem Werkstückrohling; und
• – einer Trenneinrichtung zum Entfernen des Hilfsmaterials aus dem Werkstückrohling.

Furthermore, the above object is achieved by a device for producing a workpiece from a fiber composite material according to claim 13, comprising:

• A feeding device for providing at least one carrier,
• A lay-up device for applying a main material from a pre-soaked fiber semi-finished product on at least a first region of the at least one carrier means and for applying an auxiliary material on at least a second region of the carrier means for forming at least two preform regions;
• - A molding press for pressing the two Vorformbereiche to a workpiece blank; and
• - A separator for removing the auxiliary material from the workpiece blank.

The Forming press can be a succession of pairs of opposite mold segments have, for a kraftbeaufschlagten state of the molding press along a predetermined Curve can be arranged. The flexible arrangement of the mold segments allows a any curvature and shaping a workpiece along its longitudinal direction.

A Further development provides that at least two propulsion device are provided, the two preforms parallel to the molding press, wherein a first speed of the first propulsion device and a second speed of the second propulsion device in dependence a curvature the predetermined curve are adjustable.

The The present invention will be described below with respect to preferred embodiments and using the attached Figures closer explained.

In show the figures:

1a to 1d two preforms for use in an embodiment for making a workpiece;

2a to 2c a workpiece blank, from the preforms of the 1a to 1d produced according to the first embodiment;

3a to 3c a workpiece manufactured according to the first embodiment;

4a to 4c a workpiece blank made according to a second embodiment;

5a to 5c a workpiece blank made according to a third embodiment;

6 a preform for illustrating a fourth embodiment;

7a to 7c a workpiece blank made according to the fourth embodiment;

8a to 8d Cross sections of other workpiece blanks, which are produced according to other embodiments;

9 an embodiment of an apparatus for producing a workpiece;

10 a detailed view of a molding press 9 ;

11a to 11c to illustrate a multilayer fiber composite material for use in any of the embodiments; and

12 a second embodiment of an apparatus for producing a workpiece made of fiber-fiber composites.

In The figures below denote the same reference numerals or similar Elements.

Hereinafter, a first embodiment of a manufacturing method of a workpiece made of a fiber composite material based on 1a to 1d . 2a to 2c and 3a to 3c explained.

A first preform 1 is in the 1a and 1b shown in a side view and a plan view. On a surface 2 a slide 3 , which serves as a carrier, are the material for producing the desired workpiece - hereinafter main material 6 called - in a first area 4 and an auxiliary material in a second area 5 applied. Preferably, the entire surface 2 the foil 3 through the first area 4 and the second area 5 covered.

The main material 6 is preferably a pre-soaked semi-finished fiber product (prepreg), for example with fibers of carbon. The pre-soaked semi-finished fiber can by means of a laying device, a so-called Tapeleger, machine and automated in the first area 4 on the surface 2 be applied.

The auxiliary material 7 can in the same way by a laying device in the second area 5 be applied. As auxiliary material, a semi-finished fiber product with glass fibers is particularly suitable. In the uncured state, therefore, the main material 6 and the auxiliary material 7 similar ductile properties, which advantageously do not differ substantially for a subsequent pressing operation. Furthermore, the auxiliary material 7 be fast curing.

The fat 8th of the auxiliary material 7 and main material are over the entire dimension of the preform 1 constant and equal. This results in a planar surface 9 the preform 1 ,

In the 1a to 1d is a second preform 10 shown, also from the slide 3 , the main material 6 and the auxiliary material 7 is prefabricated. As in the plan view in the 1d The third area is recognizable 11 in which the auxiliary material 7 is applied, not in one piece, but can spread over the surface 2 the foil 3 be arranged. The main material 6 is in the remaining areas 12 . 13 the surface 2 applied.

Each of two of the preforms described above 1 . 10 becomes a workpiece blank 14 formed in the 2a . 2 B and 2c in a side view and two cross sections along the planes A and B is shown.

In this exemplary embodiment, the two second preforms become 10 down along its longitudinal edge, ie towards the film 3 angled. The two profiled second preforms 10 Be back with their surfaces 9 arranged facing each other. On the left and right angled longitudinal edges of the second preforms 10 become the first preforms 1 with their surfaces 9 arranged facing the angled longitudinal edges. In this way, the results in the 2 B and 2c illustrated cross section of the workpiece blank 14 with a double-T shape. The workpiece blank 14 is along its outer surface through the film 3 covered.

The preforms 1 . 10 are now pressed together so that the preforms 1 . 10 with each other through the main material 6 stick together. The auxiliary material 7 should be selected so that it does not interfere with the material during pressing 6 sticky or otherwise bonding. Furthermore, it is advantageous if the auxiliary material 7 the same ductile properties as the material 6 has, so that the cross section of the workpiece blank 14 not deformed during pressing.

In a modification of the first embodiment, between the auxiliary material 7 and the main material 6 a release layer such as a sheet are inserted. This advantageously prevents a connection of the two materials 6 . 7 ,

In a subsequent step, the slide 3 and the auxiliary material 7 away. This results in the workpiece 15 as related to the 3a to 3c in a side view and cross sections along the planes A and B is shown. As can be seen by the comparison of the two cross sections, by the described first embodiment, a workpiece 15 are made, which has a varying cross-section. As a result, it is advantageously possible to adapt the dimensions of a longitudinal member, stringer or similar components to the design specifications without the need for manual reworking of the workpiece 15 would be required. In addition, only one tool for pressing the preforms 1 . 10 to the workpiece blank 14 required because the workpiece blank has a constant cross section over its entire length.

The workpiece 15 is then in the usual Wei cured. This can be done under pressure and / or heat.

In another embodiment, the tool blank 14 hardened. It proves to be advantageous if the auxiliary material 7 quickly hardens and thus only insignificantly a production time of the workpiece 15 extended. The cured auxiliary material 7 is then followed by the likewise cured main material 6 replaced.

The first embodiment described above can be modified in many ways. In particular, all conceivable geometric shapes and cross sections of the workpiece 15 possible. Below are several different workpiece blanks in side views and corresponding cross sections shown. The correspondingly produced workpiece and the necessary preforms can be derived from the corresponding figures by simple geometrical considerations.

In the 4a to 4c is a workpiece blank 16c which has a thicker transverse structure in the cross section A in the upper region than in the lower region of the same cross section. The foil 3 is not shown for the sake of simplicity. However, it surrounds the same 2a to 2c the entire circumference of the workpiece blank 16 ,

In the 5a to 5c is a workpiece blank 17 shown, which has a simple T-profile in its cross section. The production of this workpiece blank 17 can be done either by forming three preforms or it is first a double-T-shaped workpiece blank equal to the 2a to 2c or 4a to 4c and then cut along a longitudinal axis.

In connection with the 6 . 7a to 7c a second embodiment of the method for producing a workpiece is explained. In 6 is a preform 19 shown on a slide 3 is applied. In a first area 20 is the auxiliary material 7 directly on the slide 3 with a thickness 21 applied. The auxiliary material 7 is further characterized by a further layer of the main material 6 with a thickness 22 covered. This results in a layered structure of the preform 19 from the auxiliary material 7 and the main material 6 educated. It is essential that no main material 6 between the auxiliary material 7 and the foil 3 is arranged. Otherwise, the auxiliary material could be 7 at least partially not remove.

In a second area 24 For example, in the illustrated embodiment, it is only the main material 6 on the floor 3 applied. The thickness of the individual layers 21 . 22 respectively. 23 are chosen such that the thickness of the preform 19 is constant over its entire length.

From the preform 19 becomes the workpiece blank 25 made with a second preform. The second preform consists in this case by way of example of the main material 6 , The first two preforms 19 are angled along an edge, as in 7b seen. By using preforms 19 in those areas 20 the fat 22 of the material 6 through an underlying auxiliary material 7 is reduced, allows the production of workpiece blanks 25 and according to workpieces with any thickness of the material 6 , Accordingly, the workpiece has freely selectable wall thicknesses.

In the 8a to 8d various cross sections are shown, which can be realized by means of the previously described embodiments and preforms. It should again be noted that the cross section of the workpiece blank can be the same in all cross sections.

An embodiment of a device for producing a workpiece is shown in FIG 9 shown schematically. The device 30 has a feeder 31 for a slide 3 or another carrier. Furthermore, two more feeders 32 . 33 for the main material 6 or the auxiliary material 7 provided. The carrier 3 is along a lay-up device 34 led, which is the main material 6 and the auxiliary material 7 on the surface of the carrier 3 applies. The application of the two materials 6 . 7 and thus the production of a preform 35 . 36 can be done in a continuous process.

The two preforms 35 . 36 are guided parallel to each other and in a pressing device 37 brought in. After the entire preform 35 . 36 in the press facility 37 is arranged, the two preforms become 35 . 36 pressed together by the pressing device. As a result, the shape of the workpiece blank is impressed by the pressing device.

A separator 38 is the press facility 37 downstream. The separator 38 removes the auxiliary material from the workpiece blank. This is the slide 3 removed from the workpiece blank. Preferably, this also dissolves the auxiliary material 7 from the workpiece blank.

In 10 is a pressing device in cross-section 37 exemplified. This has pairs of opposing jaws 39 respectively. 40 on. According to the width or length of the jaw 39 . 40 a cavity is formed, the one Double T-profile corresponds.

By this illustrated pressing device 37 can the workpiece blanks of 2a to 2c getting produced.

In connection with the 11a to 11d is the structure of the material 6 on the slide 3 for a particularly preferred embodiment. The material is in successive layers 6a . 6b applied. A layer 6a has a lower layer fiber 41 on, which are arranged along a main direction. On top of that are second fibers 42 arranged, leading to the first fibers 41 an angle 43 taking. The angle is typically in the range between 30 ° and 60 °.

The fibers in the second layer 6b again have first fibers 41 on, which are arranged along the main direction. The second fibers arranged thereon 44 have an angle 45 to the main direction of the first fibers 41 on. The second angle 45 is preferably such that the third fibers 44 mirror-symmetric to the second fibers 42 with respect to the first fibers 41 are arranged. The angle 45 in this case has that to the angle 43 opposite signs.

The sequence of layers 6a . 6b of the main material 6 Ensures that when pressing the individual preforms no parallel fibers come to rest on each other. In such a case, these fibers could slip into each other and the thickness of the workpiece blank would undesirably decrease at that location.

In 12 a further embodiment of an apparatus for producing a workpiece is shown. Schematically, there are two manufacturing facilities 50 . 51 for preforms 52 . 53 shown. The manufacturing facilities 50 . 51 lead the preforms 52 . 53 in a pressing device 54 , The pressing device 54 consists of a plurality of individual molds 55 together, which are arranged in pairs opposite each other. The spatial arrangement of the paired molds 55 follows a given curved run, as in 12 shown. For this purpose, preferably the positions of the individual molds or their pairs can be adjusted. By the pressing device 54 can be produced arbitrarily curved workpiece blanks.

It turns out that with curved workpiece blanks a compression of the fiber materials of the inner preform 52 may occur. The inner preform 52 denotes the preform which has a smaller radius of curvature than the preform opposite it 53 , The compression of the fibers leads to a weakening of the mechanical properties of the finished workpiece.

This is prevented by the fact that the two preforms 52 . 53 be made with different lengths. The lengths of the two preforms 52 . 53 are adapted to the lengths that result in the finished workpiece along the two opposite surfaces. The inner preform 52 thus has a shorter length than the outer preform 53 on.

The manufacturing facility 50 . 51 lead to the two preforms 52 . 53 preferably with different propulsion speed in the pressing device 54 one. Such that the beginnings and ends of the two preforms 52 . 53 at the same time in the pressing device 54 Arrive.

Even though the present invention with reference to preferred embodiments is described, it is not limited thereto.

Especially Only a constant thickness of the preforms over the length is necessary, however the thickness over the width of the preforms vary. Also are differently designed Workpieces, as T-shaped or double-T shaped workpieces produced.

In the described embodiments are the preforms are made as separate elements. In a non-described embodiment However, it can also be a single carrier to be provided. The carrier is divided into preform areas. The preform areas correspond in their dimensions substantially the previously described separate Preforms. The main material and the auxiliary material become corresponding applied to the separate preforms on the respective preform regions. Before pressing the preform areas to the workpiece blank becomes the vehicle then folded or split along the boundaries of the preform areas.

1

preform

2

surface

3

carrier

4

Area

5

Area

6

main material

6a

location

6b

location

7

auxiliary material

9

Surface of a preform

10

preform

11

Area

12

Area

13

Area

14

Workpiece blank

15

workpiece

16

Workpiece blank

17

Workpiece blank

19

preform

20

Area

21

thickness

22

thickness

23

thickness

24

Area

25

Workpiece blank

30

making device

31

feeding

32

feeding

33

feeding

35

preforming region

36

preforming region

37

presser

38

separator

39

pressing jaws

40

pressing jaws

41

fiber

42

fiber

43

angle

44

fiber

45

angle

50

propulsor

51

propulsor

52

preforming region

53

preforming region

54

presser

55

molds

Claims (15)

Manufacturing method for a workpiece ( 15 fiber composite, comprising the following steps: (a) providing at least one carrier ( 3 ); (b) applying a main material ( 6 ) from a pre-soaked semi-finished fiber product and / or an auxiliary material ( 7 ) to the at least one carrier ( 3 ) for forming at least two preform regions ( 1 . 10 ) such that at least one of the preform regions ( 1 . 10 ) the main material and at least one of the preform regions ( 1 . 10 ) has the auxiliary material; (c) pressing the at least two preform areas ( 1 . 10 ) with each other to a workpiece blank ( 14 ) such that the at least one carrier ( 3 ) on a surface of the workpiece blank ( 14 ) is provided; and (d) removing the at least one carrier ( 3 ) and the auxiliary material ( 7 ) from the workpiece blank ( 14 ) for forming the workpiece ( 15 ). Manufacturing method according to claim 1, characterized in that in one area ( 20 ) of the carrier ( 3 ) several layers of the main material ( 6 ) and / or the auxiliary material ( 7 ) are applied such that no layer of the main material ( 6 ) by auxiliary material ( 7 ) is covered. Manufacturing method according to claim 1 or 2, characterized in that the main material ( 6 ) and / or the auxiliary material ( 7 ) each having such a thickness ( 21 . 22 . 23 ), that the thickness ( 21 . 22 . 23 ) of the preform ( 1 . 10 ) is formed homogeneously. Manufacturing method according to at least one of the preceding claims, characterized in that the main material ( 6 ) is formed as a woven fabric, a knitted fabric and / or a scrim. A manufacturing method according to claim 4, characterized in that the scrim is formed of an even number of layers, in their odd-numbered layers of first fibers ( 41 ) in a first direction and in their even layers second fibers ( 42 . 44 ) in a second direction, and the first direction is inclined between 30 ° and 60 ° to the second direction. Manufacturing method according to claim 5, characterized in that the first direction of the fibers ( 41 ) of all odd-numbered layers is the same and the second direction of the fibers ( 42 . 44 ) are arranged in the immediately successive odd-numbered layers mirror-symmetrical to each other with respect to the first direction. Manufacturing method according to at least one of the preceding claims, characterized in that the carrier ( 3 ) is formed as a film. Manufacturing method according to at least one of the preceding claims, characterized in that the main material ( 6 ) is formed as a carbon fiber material having. Manufacturing method according to at least one of the preceding claims, characterized in that the auxiliary material ( 7 ) is formed as a semi-finished product having glass fibers. Manufacturing method according to at least one of the preceding claims, characterized in that before pressing a first of the preform regions ( 1 . 10 ) parallel to a second of the preform regions ( 1 . 10 ) and then these two Vorformbereiche ( 1 . 10 ) are pressed together. A manufacturing method according to claim 10, since characterized in that the first preform area ( 1 . 10 ) and the second preform area ( 1 . 10 ) are pressed according to a curved curve. Manufacturing method according to claim 11, characterized in that the first preform area ( 1 . 10 ) with a first length and the second preform area ( 1 . 10 ) having a second length, wherein the first length of a length of the first preform region ( 1 . 10 ) after compression and the second length of a length of the second preform area ( 1 . 10 ) after pressing corresponds. Device for producing a workpiece ( 15 ) of a fiber composite material, comprising: a feeding device ( 31 ) for providing at least one carrier ( 3 ); a laying device ( 34 ) for applying a main material ( 6 ) from a pre-impregnated fiber semi-finished product on at least a first region of the carrier ( 3 ) and for applying an auxiliary material ( 7 ) at least a second region of the at least one carrier ( 3 ) for forming at least two preform regions ( 1 . 10 . 52 . 53 ); a molding press ( 37 . 54 ) for pressing the two preform areas ( 1 . 10 . 52 . 53 ) to a workpiece blank ( 14 ); and a separator ( 38 ) for removing the auxiliary material ( 7 ) from the workpiece blank ( 14 ). Apparatus according to claim 13, characterized in that the molding press ( 54 ) a sequence of pairs of opposite shape segments ( 55 ), which for a force-loaded state of the molding press ( 54 ) can be arranged along a predetermined curve. Apparatus according to claim 14, characterized in that at least two propulsion devices ( 50 . 51 ) are provided, the two Vorformbereiche ( 1 . 10 . 52 . 53 ) parallel to the molding press ( 54 ), wherein a first propulsion speed of the first propulsion device ( 50 ) and a second propulsion speed of the second propulsion device ( 51 ) are adjustable in dependence of a curvature of the predetermined curve.