EUREKA PROJECT > 5058 SPRAYFORMING
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AUSTRIA
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GERMANY
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GERMANY
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GERMANYSprayforming for production of efficient and resource conserving moulds for the plastics processing industry
The objective is the development of a novel technique based on sprayforming for a rapid and economic production of thin-wall moulds and tools for production of large-size plastic parts with a complex geometry. The tools will incorporate heating and cooling systems.
Status > FINISHED - 08-Feb-2013 Technological Area Market Area Start Date > 30-Jun-2009 Duration > 41 Months Participating countries > GERMANY, AUSTRIA | Main contactEADS Deutschland GmbH Innovations Works Dipl. Ing. Dietrich P. Jonke > Manager Thermal Spraying Organisation type > Large company |
Project Description
A profitable production of complex and large-sized plastic parts mainly depends on the fabrication of the corresponding moulds, tools and jigs. Currently these moulds are made by conventional production techniques which lead to a high heating input into the mould and therefore also require a strong cooling effort before de-moulding of the part can take place. This induces both a long cycle time and high energy consumption. Against this background the project aims at the development of a novel production technique for rapid and economic fabrication of thin-walled moulds for large-size plastic parts with a complex geometry based on the technique of thermal spraying (SPRAYFORMING). The approach of this technique focuses on near net-shape mould production as well as energy and resource efficiency by the integration of a heating and cooling system close to the mould surface. Due to in-situ diagnostics during the mould fabrication process using SPRAYFORMING and due to numeric simulation for the prediction of distortion it is expected to reduce development time and at the same time costs, in a significant way. Conditions for putting this high potential for economisation into effect is on one hand the mastery of thermal spray jets, which needs to be optimised on the data gained by in-situ diagnostics, and on the other hand a prediction of distortions generated during the build-up of particular layers allowing to abdicate upon costly material moulds or dummies. The close interaction between diagnostically gained data and numeric simulation is the crucial approach of this project and enables furthermore the tailoring of surface properties as a decisive criterion for the mould. The project comprises five work packages: WP1: Definition, Specifications for the Demonstrator moulds, Master mandrels, Benchmarks. WP2: Fabrication of moulds by SPRAYFORMING. WP3: Up-Scaling to Industrial Application. WP4: Moulds with integrated Heating/Cooling systems and in-situ Sensors. WP5: Testing of the Moulds by Processing Plastic Parts.
Technological Development Envisaged
Currently large-sized moulds with a complex and demanding geometry meant for the production of plastic parts are fabricated by conventional production techniques which lead towards a strong heating of the form and therefore require a strong cooling effort before the de-moulding of the part. This both induces a long cycle time and is very energy consuming. Furthermore the raw material input to generate such moulds is high since thick plates are joined by welding and contour shaped by milling processes leading to vast amounts of chips. A profitable production of complex and large-sized plastic parts mainly depends on the fabrication of the corresponding moulds and tools.
Main contactSCHMUHL Faserverbundtechnik GmbH & Co KG Mr. Michael Weinholdt > Head of Engineering Organisation type > SME |
Contribution to project
The organisation has the responsibility to define the requirements of tools and moulds to be developed within this project from the point of view of an end-user with vast experience and skills in this field. Furthermore any testing and evaluation of the demonstrator moulds to be developed will be carried out based on state-of-the-art know-how and SCHMUHL's daily practice.
Expertise
SCHMUHL is a manufacturer of plastic parts made of composites based on GFRP (glass-fibre reinforced plastic composite), VFRP. Applications are in the field of medical equipment, transportation systems and trucks. SCHMUHL offers a long and specific experience, due to very special requirements set and fixed by the final parts to be produced. Tailored backing structures with reinforcing bars are envisaged to be produced using sprayformed mould sheets. At the same time, tooling and moulds are assembled and adapted to the technical infrastructure to establish the interface between mould injection machines and mould locking systems. Furthermore the company SFT has gained experience with moulds and tools comprising a cavity that had been already generated by flame spraying of low melting zinc alloys. But these self established moulds did not meet the expected requirements.
Main contactUNIVERSITAET DER BUNDESWEHR MUENCHEN Prof. Dr.-Ing. Jochen Schein > Head of the Lab for Plasma Technology (LPT) Organisation type > University |
Contribution to project
In order to enable the industrial use of SPRAYFORMING, reproducible properties of thermally sprayed coatings are essential, requiring suitable monitoring and control of the coating process. The goal of this research project is to develop and adapt the necessary systems.
Expertise
The core business of the Laboratory for Plasma Technology (LPT) is the development of plasma and particle diagnostics as well as plasma generators. Examples that have found international recognition are the diagnostics Particle Shape Imaging (PSI) for the determination of properties of spraying particles like size, form and velocity, and Computer Tomography (CT) for the measurement of plasma properties including plasma jet symmetry and temperature distribution. Furthermore, the plasma generators Triplex and Delta developed at the LPT are now successful commercial products.
Main contactEADS Deutschland GmbH Innovations Works Dipl. Ing. Dietrich P. Jonke > Manager Thermal Spraying Organisation type > Large company |
Contribution to project
* Coordinator of the SPRAYFORMING project. * Coating equipment available at INNOVATION WORKS laboratories to carry out the forming process of moulds. * Integration of in-situ diagnosis equipment of partners to analyse the spray jet and later allowing correlations to predict distortion of moulds by help of software supplied by another partner. * Scale-up experiments and integration of heating/cooling systems close to the mould surface. EADS is also the end user and multiplicator to distribute the results of the project to EADS business units as well as on the project internet platform to be developed. Furthermore, publishing of results at workshops and conferences is planned.
Expertise
* Huge knowledge in surface coatings over a time span of more than 30 years regarding thermal spraying. * Pre-existing knowledge in building up thick deposits by thermal spraying for aerospace thrust chambers. * Expertise in repair of invar tools for production of CFRP parts. This led to a German patent number DE10 2006 057 638. Core business: EADS INNOVATION WORKS is the R&D facility of EADS' mother company. We develop coating techniques on behalf of our EADS customers (business units) but also for external non-EADS customers. Furthermore an investigation and characterisation of the coatings deposited is carried out and part of the requirements set by our customers. A transfer of our developments from laboratory scale to manufacturing plants and facilities is our target. INNOVATION WORKS also plays the role of multiplicator of knowledge to the public. Active membership in organisations like "Gemeinschaft Thermisches Spritzen e.V." as well as "Fachausschuss Schweissen und artverwandte Technologien AGV 7 within DIN" emphasizes this.
Main contactAlpex Technologies GmbH Dipl.-Ing. Marcel Klautzsch > Manager Sales & Technology Organisation type > SME |
Contribution to project
The organisation has several technical tasks in this project. In the first WP (work package), WESTCAM will be working on new tooling concept requirements. In the second WP, WESTCAM's main activities will be the development of innovative master model materials and a test programme to determine the machineability of thermal sprayed surfaces. In WP 3, WESTCAM will develop the necessary CAD/CAM interface for programming the spraying robot. In addition to that, thermal sprayed specific engineering rules will be developed too. Moreover, the equipment needed for the demonstrator moulds of WP3 & 4 will be designed and manufactured.
Expertise
WESTCAM FERTIGUNGSTECHNIK GMBH is a professional engineering and manufacturing partner for complete solutions in tool making and machine building. Its business activities cover the whole process chain from design concept up to manufacturing using the latest technologies. Both the aerospace & automotive industries benefit from our reliable work in design and manufacturing projects. Our expertise in the aerospace industry is the design and manufacturing of tools for CFRP (carbon fibre reinforced plastics) production. We manufacture curing tools as well as assembly or trim & drill fixtures. In the automotive field we focus on tool design & manufacturing for the production of exterior or interior plastic body panels. We offer our customers RIM tools (reaction injection moulding) for urethane as well as RTM tools (resin transfer moulding) for fibre reinforced plastics.
Main contactNeue Materialien Bayreuth GmbH Dr.-Ing. Vasily Ploshikhin > Head of Department Simulation/Metals Organisation type > SME |
Contribution to project
The organisation develops the modelling approach for the numerical calculation of the distortions and temperature distribution in the process of SPRAYFORMING. The application of the numerical simulation for the prediction of distortions generated during the build-up of particular layers by SPRAYFORMING is of crucial importance for the significant reduction of development time and costs. The numerical prediction of the temperature distribution on the mould surface during the process of SPRAYFORMING allows optimisation of the cooling and heating systems in the form-tool for an energy and time efficient process control.
Expertise
NEUE MATERIALIEN BAYREUTH GMBH is providing services in the field of new materials and materials processing. For this mission, the organisation offers high level knowledge and practical competence as well as industry-scale machines and testing facilities. The department "Simulation/Metals" has long-term and established experience in numerical simulation of material processes and properties. Furthermore, the expertise includes computer-aided development of new processes (like multi-beam welding and rapid manufacturing). NEUE MATERIALIEN BAYREUTH GMBH also provides experimental validation of developed material processes.
Main contactQuickstep GmbH Dipl. Ing. (FH) Sven Schimmel > Project Engineerg Organisation type > SME |
Contribution to project
The organisation is responsible for defining the basic requirements of tools and moulds and defining the prerequisites of the expected demonstrator tool according to the needs of the QUICKSTEP process. According to the developed test-tools and final mould geometries, QUICKSTEP will perform laminate vacuum bagging, composite manufacturing and tool-consumables compatibility trials which will be a part of testing and evaluating sprayformed moulds.
Expertise
QUICKSTEP is a new Out-of-Outoclave process developed to manufacture high performance fibre reinforced composite materials for aerospace and automotive components. QSG is a technology driver of this process and spread this novel technique among European composite manufacturing companies. Furthermore, QSG manufactures prototypes and pilot run series of components made of high performance fibres namely Carbon, glass, Aramid, etc. and polymer resin system. QSG has expertise in various fields: Quickstep-tool design, Quickstep-tool manufacturing, Quickstep machine manufacturing, Prepreg lay-up, liquid resin infusion technology, preforming techniques, laminate design and manufacturing, laminate testing and analysis.