JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 36

process

Fig. 2: Local Padup on Stiffening Stringer

Fiberforge’s RELAY® Station is used (Figure
4). This automated machine rapidly lays up
strips of unidirectional thermoplastic prepreg tape into flat, near-net-shape tailored
blanks. Multiple plies, of which the tailored
blanks are composed, are ultrasonically tackwelded to each other. Parts made with this
machine can have any laminate orientation,
ply build-ups, holes, etc., which allows for
preforms to be optimized for each part. The
RELAY Station was used to fabricate the
stiffeners for this study. Following layup,
the tailored blank is consolidated with heat
and pressure to fuse all of the plies together.
The leftmost image in Figure 5 shows two
stiffeners in lay-up form, the middle image
shows the blank after consolidation, and the
rightmost image shows the two stringers
that have been pre-trimmed prior to the
stamp-forming step.
The consolidated blank or preform (rightmost photo, Figure 5) was heated in an

external oven. At the stamping process temperature (Tp), the blank was transferred into
a mould where it was then shaped under
pressure, using a 408 metric tonne thermoforming press, to conform to the mould geometry. After forming, the blank was cooled
while still under pressure to near the glass
transition temperature (Tg) before removal
from the forming system. Springs were
used in the fixturing to provide membrane
tension on the blank to help control ply
movement during forming. The 3D part was
then trimmed into the final shape. Figure 6
shows the thermoforming process steps and
Figure 8 shows the final stiffener part.

Experimentation
Test setup
The sub-element for testing the compression
load on a stringer is shown in Figure 7 along
with the test setup. The facing C-channel
configuration is essential for maintaining

Fig. 3: Stampable cross sections

are shown in Figure 3. The arrows indicate
the direction of stamping and ensure that
there is no negative draft that would hinder
tool extraction.
The layup for C-channels in this type of
cargo load floor panel must be optimized
for bending, shear and compression. 90°
compression plies (fibres oriented in the
circumferential direction of the stringer, or
up the web) are the dominant ply orientation required. The layup in the facesheets
require a significant amount of 90° plies
(fibre oriented transverse to the stringer
axis) to counter facesheet bending between
channels.

Fig. 4: Fiberforge RELAY Station 2000 - Automated lay-up machine

Stringer manufacturing with the
Fiberforge® process
Various methods exist to fabricate composite stringers, including autoclave/
vacuum curing (thermoset resins), resin
transfer moulding (weaves and low viscosity
thermoset resins), pultrusion (thermoset
resins), and stamp-forming (thermoplastic
materials). The Fiberforge manufacturing
process is efficient for high volumes, is cost
efficient and includes four steps: automated
lay-up, consolidation, stamp-forming, and
trimming. In the automated lay-up step,

Fig. 5: Stiffener blank lay-up (left), post-consolidation (middle), and pre-form trim (right)

36 jec composites magazine / No80 April 2013



JEC COMPOSITES MAGAZINE - Issue #80 - April 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #80 - April 2013

Cover
Edito
Point of view: hig-end solutuions
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
APPLICATIONS
- Sports & leisure
- Renovation
MARKET
- Singapore
- Education
- Natural fibres
- Biocomposites
FEATURE AERONAUTICS
- Carbon
- Process
- Reinforcement
- Structure
- Bi-angle NCF
- RTM
- Sandwich
- Energy
RESEARCH & DEVELOPMENT
- CAE tools
- CFRP
TECHNOLOGY & INNOVATIONS
- Prepreg
- Material
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Point of view: hig-end solutuions
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 9
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 12
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 13
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Renovation
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Singapore
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 16
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 18
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Education
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 20
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 22
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 23
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 25
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Natural fibres
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 27
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Biocomposites
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 30
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 32
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Carbon
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 34
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Process
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 36
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Reinforcement
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 40
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Structure
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Bi-angle NCF
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 44
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - RTM
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Sandwich
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 48
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Energy
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 51
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - CAE tools
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 53
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 54
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - CFRP
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 56
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 57
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 58
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Prepreg
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 60
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 61
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - - Material
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 63
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 64
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 67
JEC COMPOSITES MAGAZINE - Issue #80 - April 2013 - 68
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