TY - CHAP A1 - Englhard, Markus A1 - Weber, Tobias A1 - Arent, Jan-Christoph T1 - Efficiency enhancement for CFRP-Prepregautoclave manufacturing by means of simulation-assisted loading optimization T2 - Proceedings of SAMPE Europe Conference 2021 N2 - A new method for improved autoclave loading within the restrictive framework of helicopter manufacturing is proposed. It is derived from experimental and numerical studies of the curing process and aims at optimizing tooling positions in the autoclave for fast and homogeneous heat-up. The mold positioning is based on two sets of information. The thermal properties of the molds, which can be determined via semi-empirical thermal simulation. The second information is a previously determined distribution of heat transfer coefficients inside the autoclave. Finally, an experimental proof of concept is performed to show a cycle time reduction of up to 31% using the proposed methodology. Y1 - 2021 ER - TY - CHAP A1 - Hailer, Benjamin A1 - Weber, Tobias A1 - Arent, Jan-Christoph T1 - Manufacturing Process Simulation for Autoclave-Produced Sandwich Structures T2 - Proceedings of SAMPE Europe Conference 2019, Nantes, France Y1 - 2019 SP - 1 EP - 8 ER - TY - JOUR A1 - Hailer, Benjamin A1 - Weber, Tobias A1 - Neveling, Sebastian A1 - Dera, Samuel A1 - Arent, Jan-Christoph A1 - Middendorf, Peter T1 - Development of a test device to determine the frictional behavior between honeycomb and prepreg layers under realistic manufacturing conditions JF - Journal of Sandwich Structures & Materials N2 - In the friction tests between honeycomb with film adhesive and prepreg, the relative displacement occurs between the film adhesive and the prepreg. The film adhesive does not shift relative to the honeycomb. This is consistent with the core crush behavior where the honeycomb moves together with the film adhesive, as can be seen in Figure 2(a). The pull-through forces of the friction measurements between honeycomb and prepreg at 1 mm deformation are plotted in Figure 17(a). While the friction at 100°C is similar to the friction at 120°C, it decreases significantly at 130°C and exhibits a minimum at 140°C. At 150°C, the friction rises again slightly and then sharply at 160°C. Since the viscosity of the M18/1 prepreg resin drops significantly before it cures [23], the minimum friction at 140°C could result from a minimum viscosity of the mixture of prepreg resin and film adhesive before the bond subsequently cures. Figure 17(b) shows the mean value curve of the friction measurements at 140°C. The error bars, which represent the standard deviation, reveal the good repeatability of the tests. The force curve is approximately horizontal between 1 mm and 2 mm. The friction then slightly rises. As with interlaminar friction measurements, this could be due to the fact that resin is removed by friction and the proportion of boundary lubrication increases. Figure 18 shows the surfaces after the friction measurement. The honeycomb cell walls are clearly visible in the film adhesive. There are areas where the film adhesive is completely removed and the carrier material of the film adhesive becomes visible. In addition, the viscosity of the resin changes as the curing progresses during the friction test. This can also affect the force-displacement curve. Y1 - 2020 U6 - http://dx.doi.org/10.1177/1099636220923986 SN - 1530-7972 IS - Volume 23, Issue 7 SP - 3017 EP - 3043 PB - Sage CY - London ER - TY - JOUR A1 - Otten, Dennis A1 - Weber, Tobias A1 - Arent, Jan-Christoph T1 - Manufacturing Process Simulation – On Its Way to Industrial Application JF - International Journal of Aviation, Aeronautics, and Aerospace N2 - Manufacturing process simulation (MPS) has become more and more important for aviation and the automobile industry. A highly competitive market requires the use of high performance metals and composite materials in combination with reduced manufacturing cost and time as well as a minimization of the time to market for a new product. However, the use of such materials is expensive and requires sophisticated manufacturing processes. An experience based process and tooling design followed by a lengthy trial-and-error optimization is just not contemporary anymore. Instead, a tooling design process aided by simulation is used more often. This paper provides an overview of the capabilities of MPS in the fields of sheet metal forming and prepreg autoclave manufacturing of composite parts summarizing the resulting benefits for tooling design and manufacturing engineering. The simulation technology is explained briefly in order to show several simplification and optimization techniques for developing industrialized simulation approaches. Small case studies provide examples of an efficient application on an industrial scale. Y1 - 2018 U6 - http://dx.doi.org/10.15394/ijaaa.2018.1217 SN - 2374-6793 VL - 5 IS - 2 PB - Embry-Riddle Aeronautical University CY - Daytona Beach, Fla. ER - TY - JOUR A1 - Weber, Tobias A1 - Arent, Jan-Christoph A1 - Münch, Lukas A1 - Duhovic, Miro A1 - Balvers, Johannes M. T1 - A fast method for the generation of boundary conditions for thermal autoclave simulation JF - Composites Part A N2 - Manufacturing process simulation enables the evaluation and improvement of autoclave mold concepts early in the design phase. To achieve a high part quality at low cycle times, the thermal behavior of the autoclave mold can be investigated by means of simulations. Most challenging for such a simulation is the generation of necessary boundary conditions. Heat-up and temperature distribution in an autoclave mold are governed by flow phenomena, tooling material and shape, position within the autoclave, and the chosen autoclave cycle. This paper identifies and summarizes the most important factors influencing mold heat-up and how they can be introduced into a thermal simulation. Thermal measurements are used to quantify the impact of the various parameters. Finally, the gained knowledge is applied to develop a semi-empirical approach for boundary condition estimation that enables a simple and fast thermal simulation of the autoclave curing process with reasonably high accuracy for tooling optimization. Y1 - 2016 U6 - http://dx.doi.org/10.1016/j.compositesa.2016.05.036 SN - 1359-835X VL - 88 SP - 216 EP - 225 PB - Elsevier CY - Amsterdam ER - TY - JOUR A1 - Weber, Tobias A1 - Arent, Jan-Christoph A1 - Steffen, Lucas A1 - Balvers, Johannes M. A1 - Duhovic, Miro T1 - Thermal optimization of composite autoclave molds using the shift factor approach for boundary condition estimation JF - Journal of Composite Materials Y1 - 2017 U6 - http://dx.doi.org/10.1177/0021998317699868 SN - 1530-793X VL - 51 IS - 12 SP - 1753 EP - 1767 PB - Sage CY - London ER - TY - JOUR A1 - Weber, Tobias A1 - Englhard, Markus A1 - Arent, Jan-Christoph A1 - Hausmann, Joachim T1 - An experimental characterization of wrinkling generated during prepreg autoclave manufacturing using caul plates JF - Journal of Composite Materials Y1 - 2019 U6 - http://dx.doi.org/10.1177/0021998319846556 SN - 1530-793X VL - 53 IS - 26-27 SP - 3757 EP - 3773 ER - TY - CHAP A1 - Weber, Tobias A1 - Englhard, Markus A1 - Hailer, Benjamin A1 - Arent, Jan-Christoph T1 - Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling T2 - Proceedings of SAMPE Europe Conference 2019, Nantes, France Y1 - 2019 SP - 1 EP - 10 ER - TY - CHAP A1 - Weber, Tobias A1 - Englhard, Markus A1 - Hailer, Benjamin A1 - Arent, Jan-Christoph T1 - Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling T2 - Proceedings of SAMPE Europe Conference, Amiens , France Y1 - 2015 SP - 1 EP - 10 ER -