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Integrated approach aids move to closed moulding The composites industry is moving inexorably away from its humble origins towards more mechanised and efficient manufacturing processes. Stephen Leonard-Williams and Richard Bland of the UK’s Composite Integration Ltd explain how their company helps moulders to set up successful closed moulding operations.
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imple contact moulding (hand or spray lay-up) is, inevitably, becoming less and less tenable. Environmental concerns about emissions within and from the workplace have led to ever tighter legislation. Moreover, composites are increasingly competing with more ‘conventional’ materials in high specification applications, which demands more sophisticated, efficient and better controlled manufacturing processes. The group of processes broadly described as ‘closed moulding’ (resin transfer moulding (RTM), RTM Light, vacuum assisted RTM (VARTM), for example) go a long way towards resolving the emissions issues usually associated with contact moulding and lend themselves admirably to automation, opening the way to high volume production of sophisticated composite structures with precisely controlled laminate thicknesses and fibre placement. Composites polymers is currently one of the most innovative and rapidly expanding fields of engineering worldwide. Indeed, the 'Infrastructure Composites Report' 2001 published by Composites Worldwide predicts that globally, the use of composites will grow by more than 525% between 2000 and 2010. However, the rapid and rather haphazard step-up from very 'low-tech' contact moulding methods to more sophisticated techniques is creating real confusion for many composites fabricators. Successful management of this transition
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will be a key issue in the future survival of the composites industry.
Successful management of the transition from contact to closed moulding will be a key issue in the future survival of the composites industry. Process implementation One major cause of confusion for those moving into closed moulding is a lack of relevant education and training in composites-related subjects. Moulders are increasingly encouraged to improve their skill and knowledge base, but specific process-related training is often left to the suppliers of processing equipment and raw materials. To successfully move into new and more complex composites manufacturing processes, it is vital to ensure an efficient transfer of information based on sound practical knowledge. The implementation of a new production process can be broken down into several specific stages. Each stage brings its own diverse challenges and the boundaries between them can be quite 'grey'. A typical sequence might be: • feasibility — is the design of the product suited to the manufacturing process?;
• • • • • • •
materials selection; equipment selection; tooling design; tooling construction; production set-up and installation; training; and technical support.
Within the composites industry, the management of this process is often poorly supported. Moulders wanting to implement a new process have two possible sources of help: technical support from specialist equipment/material suppliers; or formal composites training from an academic body. Support from suppliers will usually be given enthusiastically and has the added advantage of being free. However, there is an inevitable bias favouring that company's wares and few manufacturers have the resources to offer more than 'just enough help to get started'. Often, the help supplied is limited in its presentation and scope but, being part of a selling process, there is usually no cost to the moulder. This, in itself, has made the industry reluctant to invest properly in this vital stage. The alternative, academic training, can provide a good insight into theoretical issues but is inevitably rather limited when it comes to transferring theory into a production environment. Whilst a sound academic knowledge is an excellent basis from which to start, there is no substitute for practical hands-on experience and assistance. 0034-3617/03 ©2003 Elsevier Ltd. All rights reserved.
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Integrated approach Composite Integration was formed in 2002 with the express aim of assisting composite manufacturers wishing to move into closed moulding processes by providing an integrated and systematic approach. This is normal, production engineering practice when installing a new manufacturing solution. Processes are selected, materials identified, equipment is procured, personnel are trained and a production environment is designed and implemented. The company is based on a combined experience of 30 years manufacturing equipment and tooling for RTM type processes, and is able to offer this experience at any stage. The company aims to avoid the label of 'consultancy' but provides practical assistance in all key areas. This help often starts with input at the component design stage. The tendency to simply copy components that were originally designed for a completely different process or indeed, material, has often led to manufacturing problems. For instance, parts designed for compression moulding processes will typically have details (ribs, webs etc) that are not only impractical to mould in an RTM/VM process, but are also often unnecessary, due to the scope for more controlled fibre management. Help to 'design for process' can pay real dividends in production. The next stage would be to identify the best tooling option, and to specify peripheral equipment (injection machinery, vacuum plant, tool manipulation and clamping devices and materials handling). Finally, assistance can be provided to ensure that the process continues to run smoothly in production and that personnel are suitably trained. Demand for this service, since the launch of the company, has been substantial. There is little doubt that the adoption of this approach can have a significant influence on the successful outcome of projects of this nature.
Tool building As well as technical assistance and training, the company also builds tools and
Table 1: Comparison of closed moulding techniques Vacuum moulding/RTM Light - usually composite tooling
Against: • Tool life must be carefully balanced against cost • Tool manufacture must be carefully controlled at all stages • Tooling must be meticulously maintained to achieve maximum life
For: • Often used as an 'entry level' process but possible to scale up to higher volume production (>2000 per annum). • Tooling significantly cheaper than RTM (approx 40% saving) with the possibility of using existing 'open' tooling as starting point • Tooling can be manufactured in-house with the appropriate training • Short tooling lead times • Light weight tooling poses less handling problems • Very 'scalable' with large structures (>20 m²) being achievable
RTM- metal tooling For: • Tool life- very high production numbers possible (>10,000) • Balance between tool cost and tool life can render metal significantly cheaper than composite if production numbers are suitable. • Tooling can be cut directly from CAD data without the need for a 'pattern' • Very fine detail/surface finishes are achievable • High temperature, pressure and abrasion resistance are inherent features • Certain shapes can actually be cheaper to produce in metal than as a composite structure
Against: • Laminate thickness control less precise than RTM • relatively labour intensive and difficult to automate
RTM - composite tooling For: • Relatively short lead times and tooling can be manufactured in house with the appropriate training • Automation is possible, with good control over process variables • Rigid tooling allows faster injection and thus shorter cycle times • Tooling can be produced from a conventional 'pattern' without the need for CAD data.
Against: • Larger structures can be prohibitively expensive either to machine or simply in material cost • Specialist expertise needed to avoid costly mistakes • Weight. tool handling infrastructure can add significant cost
teaches others how to do so. This extends to a complete training service for RTM and vacuum processes. Tooling is a recognised 'weak link' in newly implemented moulding processes, failure often being caused by a lack of understanding of the basic principles of the moulding process and the materials involved. Consequences can range from premature mould failure to inaccurate, inconsistent or wasteful production. Much of our industry relies on tooling produced 'in-house', with traditional tried and tested techniques. Many of these systems work adequately, but, tool construction is often perceived as a 'black art' with many conflicting views as to the best route to take. Tooling for closed mould applications is invariably more costly to manufacture than the simple tools used in contact
moulding techniques. Consequently, issues of longevity and efficiency are of prime concern. The choice of tooling materials, and the detailed design of the structure, is vitally important in achieving a workable solution. However, the number of completely different tooling 'systems' currently marketed makes this choice even more confusing. Tooling options can range from relatively simple and inexpensive composite structures to fully machined metal, and the decision as to which direction to go is not always obvious. Table 1 (above) compares the different options available. The information is by no means exhaustive but covers some of the issues involved.
Case studies Composite Integration is employed in a diverse range of areas, ranging from
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2.
3. A resin transfer moulded composite door skin.
highly structural carbon/epoxy aerospace components to vehicle body panels. Two current projects, with very different end products, give an insight into some of the activities needed when introducing a closed mould process. The first is a project to manufacture a seemingly simple product but in high volumes. This is coupled with a requirement for extremely high cosmetic quality. The customer, New World Developments Ltd of Northern Ireland, manufactures composite door skins and asked Composite Integration to design, specify and install an RTM manufacturing plant with the capability to produce more than 20 000 door skins per annum in a number of designs. The different stages of the project break down as follows: 1. Liase with product designers to ensure suitability for the chosen manufacturing process. A high level of detail is
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required on both A & B surfaces which must be both practical to machine (as tooling) and to mould in composites. Identify suitable materials (glass, resin, release agents etc). A highly reactive modified acrylic resin system is chosen that will allow a six minute cycle time. Design tooling, injection gating, venting and seal profiles. An essential requirement is a feature which allows the tools to be changed quickly to accommodate eight different designs. Identify tooling suppliers able to produce the moulds within the time scale and budget. The tooling is rendered more complex by the requirement for a grained surface finish which is achieved by acid etching as a postmachining operation. Specify tooling materials. In this case tooling grade aluminium is chosen for its toughness and suitability for the various machining processes. Specify the surface treatment of the tooling blocks to withstand the abrasion of the glass fibre reinforcement. Specify the necessary hydraulic press and identify supplier. The rapid cycle time requires very high speed injection of the resin. The clamping press must potentially provide 1600 kN of force to resist injection pressure and maintain thickness accuracy.
The moulded door skin is demoulded from its press and tooling.
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Fibre preparation of a composite strut.
Composite strut component undergoes testing.
8. Specify injection equipment and identify supplier. 9. Integrate equipment for automation. 10. Specify materials handling equipment and identify suppliers. Bulk resin mixing must allow the addition of accelerators, fillers and pigments. 11. Liase with all suppliers throughout production to identify any problems and ensure key targets are met. 12. Design layout of the production area. The production area must provide a smooth process flow and be suitable for future expansion. 13. Oversee installation and commissioning of the equipment. Testing of various raw materials provides prototype panels for testing. 14. Train operators in use of the equipment and materials and provide ongoing assistance once full production is underway. The second example is in distinct contrast. The project is to develop a high fibre volume composite structure as a direct replacement for an existing noncomposite component. Customer Vortok International (part of the Pandrol Group, a specialist in the
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design of products for the maintenance of railway track and infrastructure) wanted to produce a composite strut which could withstand high tensile and impact loads. This resulted in a glass/epoxy moulding with complex geometry which includes metallic and polymer inserts encapsulated within the laminate. Composite Integration’s project aim was to produce pre-production tooling and prototype mouldings for product evaluation and testing based on laminate design provided by the Advanced Composites Manufacturing Centre, Plymouth University, UK. The final design is to be developed into a viable production process. The project activities are as follows: 1. Assist during design to ensure practicality at the moulding stage. 2.· Design and build heated composite RTM moulds for the various components. The tooling must be able to accurately locate the various inserts and allow injection under vacuum to gain full wet-out of the tightly packed fibre. 3. Assess the fibre lay-up and develop a practical way of producing the required fibre preform. The design requires 50% (volume) of almost entirely unidirectional (UD) glass fibre with a requirement for transferring maximum tensile loads to the metallic inserts at either end. 4. Identify suppliers for the various UD glass tapes, multiaxial cloth and rovings. 5. Identify a suitable epoxy resin system. The resin must allow rapid and relatively low temperature cure (<60ºC) without compromising the physical characteristics. 6. Manufacture prototype components whilst developing a viable production process. 7. Work with the customer to make any modifications to the design/tooling based on test results.
INNOVATION IN CLOSED MOULDING As part of our commitment to providing practical, economic, reliable process technology, we are proud to announce the launch of the V400 Injection Valve (patent pending) for use in both RTM and VM/RTM light applications.
V400 Injection Valve patent pending
Highly reliable operation with very low maintenance requirement Unique design enables use with filled, unfilled, DCPD polyester and epoxy resin systems without modification. Allows access into deep mould structures Ergonomic design with simple disassembly Lower cost. Affordable for use with VM/RTM light.
Installation of more than 30 valves at one of the UK’s largest closed mould manufacturers has demonstrated 100% reliability over an 8 month period.
The key to success Closed moulding is now an accepted route to producing high quality and potentially complex structures. When making the transition, however, more people fail than succeed, with too many projects resulting in disillusionment and wasted investment. Why does this happen when there is sufficient evidence of very successful operations to indicate that it need not be so? One answer is a lack of professional guidance. The key to most successful operations has been the use of sound engineering principles, combining theoretical knowledge with practical and relevant experience. Investing in this expertise is probably the most cost-effective decision that any company can make if considering the closed mould option. ■
Composite Integration can offer practical help with your closed mould project from simple composite tooling to fully automated production systems.
Tooling
• Mould Ancillaries • Training • Equipment • Turnkey Systems •
Stephen Leonard-Williams, Composite Integration Ltd; tel: +441752-849998; fax: +44-1752-849808; e-mail: info@ composite-integration.co.uk; website: www.composite-integration.co.uk.
Tel: +44 (0)1752 849998 Fax: +44 (0)1822 849808 Web: www.composite-integration.co.uk email:
[email protected] Unit 7 Saltash Business Park, Saltash, Cornwall. PL12 6LX. UK
RES No. 315 – USE THE FAST NEW ENQUIRY SERVICE @ www.reinforcedplastics.com November 2003
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