Research Themes

Processing Research

ctw/pt

Automated Composites Manufacturing is concerned with the cost-effective application of advanced continuous fibre reinforced composites.

The breakthrough of this type of materials in various applications has occurred to a smaller extent than might have been expected, mainly due to their high costs of manufacturing. Hence, the research activities focus on:

  • Repeatable, high accuracy in series production mouldings in order to avoid scrap, reduce rework and achieve closer fit of assemblies
  • Cheaper production processes and a higher production rate by e.g. (rubber) forming of fibre reinforced thermoplastics, thermoplastic tape placement and liquid composite moulding of fibre reinforced thermosets.

The research philosophy consists of thorough (often experimental) analysis of the deformation and flow mechanisms involved during fabrication and subsequent modelling of these mechanisms. Design tools are developed to support the production of composite materials with modern techniques. The aim of these design tools is mostly to predict the process settings necessary to obtain a composite component having a prescribed shape or combination of materials properties.

Click on the author’s name to obtain more information about the project.

FIBRECHAIN

Integrated Process Chain for Automated and Flexible Production of Fibre-Reinforced Plastic Products

2011-2015

Staff

The FIBRECHAIN project aims at the development of transferable manufacturing systems for the automated and robust customized production of small and medium sized lots of continuous carbon, glass, basalt and natural fibre-reinforced 3-D shaped and multi-layered thermoplastic lightweight structures.

Contact

Bert RietmanRemko Akkerman

Partners

EU: FIBRECHAIN,

Complex Stamp Forming


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2010-2012

Staff

Sebastian HaanappelUlrich Sachs

Thermo forming of multi-layer thermoplastic composite laminates is a fast and cost effective method to produce thin shelled products. The long term objective of this project is to accomplish affordable optimized press formed components with local thickness and lay-up variations. Guidelines for design and processing are required to achieve this objective and will pave the way for further implementation of this technology.

TPRC

Contact

Remko Akkerman

Partners

TPRC, Aniform

Key Publications

Haanappel, ECCM, 2010
Akkerman, TEXCOMP, 2010

Tow Mechanics: Meso and Micro tow deformation behaviour

2008-2012

Staff

Bo Cornelissen

The deformation of dry or pre-consolidated fabrics is mostly described by considering the fabric as a continuum. This research focuses on the meso and micro scale in order to improve the deformation description. The mechanisms at this scale are identified and described.

Contact

Remko Akkerman

Partners

Teijin Aramid, PPG

Key Publications

Cornelissen, ICEM, 2010

Friction Stir Welding

Local Alloying and Cladding of Advanced Aluminium Alloys


2009-2013

Staff

Arnoud van der Stelt

Friction stir welding is a relative new, solid state welding technique. It uses a rotating, non-consuming tool to locally heat up and deform the materials to be joined. In this research project this principle is used to develop new FSW tools and simulation models to deposit thin layers on top of a work piece. Various surface properties can be improved in this way, such as corrosion resistance.

Contact

Ton Bor

Partners

M2i, NLR

CleanSky EcoDesign LATP

Optimisation of the Laser Assisted Tape Placement Technology


2008-2012

Staff

Wouter Grouve

In this part of EcoDesign, the Laser Assisted Tape Placement technique, where a thermoplastic composite tape is thermally adhered on a thermoplastic composite substrate, is optimized for performance, and ultimately to reach in-situ consolidation.


Contact

Laurent WarnetRemko Akkerman

Partners

EcoDesign, AFPT, TUDelft, Eurocopter

Key Publications

Grouve, Int. J. of Mat. Forming, 2010


Interlaminar shear in fabric in melt condition


2007-2009

Staff

René ten Thije

Recent projects concerned with the prediction of forming induced deformation of thermoplastic composites have depicted the most relevant mechanisms. It was shown that friction plays a dominant role in most of the mechanisms involved. Both tool-ply and ply-ply friction are the subject of this study, where an experimental set-up is built to derive a constitutive model. A describing model specific for woven fabric is developed in parallel.


Contact

Remko Akkerman

Partners

NIVR

Key Publications

Thije ten, Int. J. of Mat. Forming , 2009
Thije ten, Composites A, 2009

Optimisation of the consolidation process of thermoplastic composite laminates

2007-2009

Staff

Wouter Grouve

This project gives an improved understanding of the fundamental mechanisms playing a role in the impregnation and consolidation of film-stacking based fibre-reinforced thermoplastic laminates. This knowledge led to a processing parameters predicting engineering tool. The primary aim of this tool is to reduce the processing time.


Contact

Remko Akkerman

Partners

NIVR, Ten Cate AC, Reden

Key Publications

Grouve, Plastics, Rubber and Composites, 2010

Processing prediction for enhanced design with NCF Composites


2002-2006

Staff

René ten Thije

The draping of Non Crimp Fabric was studied, leading to a NCF deformation prediction tool. Such a tool is essential for both impregnation analysis and mechanical performance analysis. The FE tool is based on decomposition of the fundamental mechanisms occurring when draping such a fabric. The FE tool is able to describe these basic mechanisms, often involving large deformations, and to predict the deformation of a complex shaped demonstrator.

Contact

Remko Akkerman

Partners

EU: FALCOM

Key Publications

Thije ten, PhD Thesis, 2007
Thije ten, Comp. meth. in Appl. Mechs. & Eng. , 2007

Thije ten, Composites A, 2008

Resin Transfer Moulding – Development of predictive models for the permeability of fibre reinforcements


2001-2006

Staff

Richard LoenderslootBlasimir Silva Rodriguez

In collaboration with the NLR, a relation between preform geometry, as obtained for example with a braiding process, and permeability is proposed. Both in-plane and out-of-plane permeability are considered.

Contact

Remko Akkerman

Partners

NLR, EuroCarbon, Polyworx, Fokker

Key Publications

Loendersloot, PhD Thesis, 2006
Akkerman, TEXCOMP, 2006

Shape distortions in fabric reinforced composite products due to processing induced fibre reorientation and stresses


1998-2004

Staff

Edwin LamersSebastiaan Wijskamp

In this research starting with the European project Precimould, a numerical tool is developed for high precision composite forming. In particular rubber pressing of thermoplastic composites is considered.


Contact

Remko Akkerman

Partners

EU: Precimould, NIVR MRP, Stork Fokker, TCAC

Key Publications

Lamers, PhD Thesis, 2004
Wijskamp, PhD Thesis, 2005

Lamers, Int. J. of Forming Processes, 2003