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2008
Conference Paper
Titel
Advanced manufacturing of large, complex foam core sandwich panels
Abstract
Infusion strategies for large, complex CFRP foam core sandwich panels with closed cell foam cores were investigated for open mould liquid composite moulding (LCM) technologies. For closed cell foam core no through the thickness resin flow is possible. If no through the thickness channels in the foam core are being introduced (e.g. open holes, core joints, pins, etc.) the infusion of the sandwich requires resin distribution media on both skins. In a first approach standard distribution medium was used. In a second step a tool integrated resin distribution system was developed for the infusion of the tool-sided skin. To demonstrate that aerospace quality is achievable manufacturing trials with monolithic specimen and complex sandwich panels including damage containment, load introduction and tool integrated resin distribution technology were carried out in a laboratory environment. The investigations show that aerospace quality can be achieved for large CFRP sandwich panels in LCM technology. However the achievable quality depends heavily on the panel/component materials, design details, geometry and the chosen technology approach and strategy for the infusion. Besides the quality factors todays composite aeronautical components have to meet the demand of the market for low cost structures and high production rates. Therefore an industrial concept approach for LCM of CFRP foam core sandwich panels was developed. Conceptual approaches for the key factors of the automation - the automated handling and preforming of the sandwich component are shown in this paper as well as the results of practical automation trials. Full automation of the manual sandwich lay up process for the considered component complexity is possible. This automation technology has large potentials to increase the profitability and the quality of the parts manufacturing.