Welcome to the articles that were included in the Autumn 2011 Newsletter. To subscribe please send an email to info@compositesuk.co.uk with Subscribe Composites UK in the subject line.

Composites UK at Composites Engineering Show - Stand 336

 

Composites UK will be exhibiting at the Composites Engineering Show on the 9th and 10th November 2011 at the NEC in Birmingham on stand 336.

 

The association is again Headline Industry Partner for the event therefore a highlighted presence will be seen throughout the exhibition. Composites UK has also been working hard with the organisers, UK Tech Events, to bring you exciting and informative forum sessions. More information on these sessions can be found by clicking here.

 

Stand 336 will be manned by both the administration team and the board of directors therefore if you have any questions about the association either as a member or non member please feel free to drop by or make an appointment by emailing info@compositesuk.co.uk or call +44 (0)1246 266244.

Biocomposites Subgroup News

 

Composite materials derived from natural, renewable sources have received significant interest in recent years, in particular due to the increased awareness of environmental issues and the drive towards more sustainable technologies. The materials offer unique advantages over alternative choices, but there are many questions still to be answered from potential end-users and from within the composites community itself. Within this in mind, Composites UK has launched its BioComposites sub-group to support and guide companies looking to either produce or use these materials.

 
The first meeting of the group held on 6th October in Reading tackled some of the fundamental questions posed by the composites industry and end-user markets. The workshop was facilitated by Alex Edge, E-Tech and Chair of Composites UK Biocomposites subgroup.

 

Some key outcomes from the meeting were:

 

• High tech biocomposite development means that bio materials are now being used in structural applications
• The supply chain for biocomposites is now able to cope with industrial demand
• There is a real opportunity now to use biomaterials in the same way as conventional composites – properties can be comparable and costs importantly have come down
• Biocomposites offer a step towards sustainable manufacturing

 

There are some challenges ahead in terms of durability data, LCA accountability and education. The Biocomposites group is developing a strategy to work alongside academia, industry and end-users to address these issues, and advise and support in the implementation of these materials.

 

Details of suppliers, designers and manufacturers of biocomposite components can be found through the Composites UK database: http://www.compositesuk.co.uk/MembersDirectory/searchmaterials.asp?search=true

 

For more information please contact Alex Edge, Chair BioComposites subgroup
 

H&S Audit and Award Scheme

This summer saw the launch of Composites UK's H&S audit and award scheme. This is a scheme where a processing company is audited by a member of the H&S working group with the focus on H&S management systems and risk assessments. The audit typically takes a half day, and assuming satisfactory performance, leads to a H&S award from level 1 to level 5 depending on the comprehensiveness of systems and compliance. Alternatively, a self-audit format is possible with completed documentation being forwarded to the secretariat.

We are delighted to announce that two member companies, Composite Fibreglass Mouldings and Lamplas Polymer Engineering, have participated in the scheme and have received awards.

Please contact the administration team should you wish to participate in this scheme which will also ensure you start to comply with the HSE SIMPL initiative.

 

Semta develops series of new National Occupational Standards to support Composites sector

 

Semta, the Sector Skills Council for science, engineering and manufacturing technologies has announced a new suite of 18 National Occupational Standards (NOS) for composites occupations, to ensure that businesses have the skills they need to thrive through the economic recovery.

 

Developed by Semta and approved by the employer-led Composites Skills Strategy Group (SSG), the new standards cover specialist areas such as producing composite mouldings, applying surface finishes, identifying defects and carrying out repairs. Occupational standards provide a description of the skills, knowledge and understanding needed to undertake a particular task or job to a nationally recognised level of competence, helping formalise training requirements for employers and employees.

 

Ken Wappat, Chairman of the Composites Skills Strategy Group said: “I am delighted that the Composites Skills Strategy Group has approved the new composites national occupational standards. We are grateful to Semta for developing these standards which will underpin vital qualifications for the sector, covering the processes and technologies relevant to today's composite manufacturing techniques."

 

The UK composites market is intrinsic to the growth of Semta’s sectors overall, with composites playing a part in most modern engineering and manufacturing businesses. Composites – a crucial part of the Advanced Manufacturing agenda – comprise a mixture of two or more discrete materials, which when combined create a material with stronger mechanical properties such as low density, greater strength, corrosion resistance and lower maintenance. They are used to manufacture everything from aeroplane parts to baseball bats.

 

Philip Whiteman, Chief Executive of Semta, said: “During the recent difficult economic environment, businesses have increasingly focused on the return on investment that skills and training deliver. The new National Occupational Standards will ensure that the businesses are getting the right kind of skills, and that their delivery is of a consistently high quality, regardless of training provider or organisation. “We know that composites are vitally important to businesses in our sectors so, by concentrating on establishing a suite of National Occupational Standards specifically for the industry, we are meeting the needs of employers and helping our sectors gear up for growth.”
 

Website: http://www.semta.org.uk/about_us/media_centre/news/semta_composites_nos.aspx

 

Lamborghini Chooses FORMAX's Carbon Multiaxial Fabrics to Reinforce its Latest Carbon Supercar

 

Lamborghini’s challenge to FORMAX was to develop a range of balanced materials that would combine drapeability, good structural properties, and an innovative method of binding the materials in a preform structure prior to injection.

 

FORMAX’s product engineers worked closely with our carbon specialist Paolo Grati, and Lamborghini's design team, to define the best fabrics for Lamborghini’s innovative production process.

 

The resulting quadaxial structures, stitched with FORMAX’s “tacky-stitch” specifically designed for preform applications, were refined many times before the final optimised version was finally chosen by Lamborghini to reinforce the chassis for their brand new carbon supercar.

 

FORMAX is proud to be part of such an exciting and innovative project that proves that with the right fabrics, carbon fibre can be processed at speeds and efficiencies conducive with high volume automotive manufacturing processes.

 

Website: www.formax.co.uk

 

 

Manufacturing Excellence Produces Extraordinary Results

In an industry where quality, discretion and professionalism are paramount, Atlas Composites lead the way when it comes to the design and manufacture of next generation composite structures.
Already established as one of the UK’s most accredited and trusted composites manufacturers, this week sees Atlas Composites take another significant step towards Supply Chain 21st Century (SC21) recognition.

Aided by strategic partner TPT Consultancy & Training, the end of September signals the end of a remarkable year long audit for the East Midlands based composites manufacturer with the announcement of their latest set of Key Performance Indicators (KPI’s).

With a growing number of customers and suppliers recognising the benefits of achieving an SC21 benchmark the future certainly looks promising for Atlas Composites after they delivered an impressive Quality Performance (right first time) KPI of 99.6% and a faultless On Time Delivery KPI of 100%.

Atlas Composites design and manufacture a diverse range of carbon, kevlar, glass and aramid fibre composite components and tooling for Aerospace, Defence and the Satellite Communications industry.

Website: www.atlascomposites.com

 

NetComposites Display Recycled Carbon Fibre Parts at Composites Europe 2011

NetComposites displayed automotive brackets made from recycled carbon fibre at the Composites Europe Show this month.

According to NetComposites, the parts have been developed using a new generation of high performance, low cost co-mingled carbon fibre yarns that were the outcome of the recently concluded multi-partner project, Fibrecycle. The yarns and fabrics are blended carbon/PET, manufactured from virgin recovered carbon fibre that would otherwise have gone to landfill and that these new materials have almost 100% of the stiffness of virgin materials. They can be offered at a lower cost than similar products currently available on the market. They say they are also beneficial to the environment and retain the traceability of virgin materials.

Fibrecycle, which completed in August, was a UK funded research project composed of six partners: Advanced Composites Group Ltd (ACG), part of Umeco Composites Structural Materials (UCSM) – a Division of Umeco plc, Tilsatec, Sigmatex, Exel Composites UK, NetComposites and the University of Leeds. The project produced yarns, sliver and tape, together with both woven and non-crimp fabrics. Composite laminates have been press-moulded, showing that the carbon/PET (50:50 weight ratio) composites offer at least 50% of the tensile strength and 90% of the tensile modulus of an equivalent composite based on virgin fibres.

As worldwide carbon fibre composite usage grows, there is concern about the potential tonnage of waste from manufacturing processes and end-of-life products. The waste related to carbon fibre products will quickly reach a significant level to become an important environmental issue, so there is a strong interest in developing processes for recovering and recycling carbon fibre from waste materials.

NetComposites have created Visteon automotive brackets using the non-crimp fabric with PET which significantly reduces the weight of the brackets which were traditionally made out of metals. These brackets are undergoing various mechanical tests. Mohammed Riaz, NetComposites Development Engineer said "The new materials are ideal for the automotive industry. They offer great strength and are lightweight meaning they are ideal for non-critical load parts".

Website: www.netcomposites.com

 

Flaxland Create Canoe from Composites Evolution's Biotex Flax
 

The canoe has been built by Flaxland, in the UK, and is made from 1 layer of Biotex Flax Hopsack weave and a UV cured bioresin (EcoComp UV-L resin), provided by Sustainable Composites. It is constructed using a marine plywood and European pine frame, that is covered using the Biotex material, then impregnated with the linseed based EcoComp UV-L resin.

Simon Cooper, owner of Flaxland, is a traditional boat builder with a strong interest in using all natural materials. “In recent years synthetic materials, such as coated polyester fabrics, have been used more and more in boatbuilding. In an attempt to return to traditional boatbuilding methods, I became interested in the use of Flax as a sustainable crop for the production of oil and fibre to make a boat. I wanted to find new, novel, but natural materials, and in my search found the Biotex website” he explained.

Flaxland trialled many flax fabrics and found that Biotex suited the needs of the project best. Owner, Simon Cooper felt that Biotex had good impregnation, wet out and very good tear strength which was equal to the synthetic materials allowing for a flexible yet strong canoe which could be been made without the use of a mould tool.

 
Flaxland have made a total of 7 prototypes so far, using both the Biotex Flax Hopsack and Biotex 3H Satin weaves. The Hopsack version offers a resilient and durable canoe which has a net weight of just less than 12Kg and the Satin version gives a lighter weight option, at just 8Kg, for racing.

The canoe is currently undergoing long term durability and water resistance tests and, according to Simon, has shown good results for over one year already. He is now looking to roll out the design to larger rowing boats.

Website: www.compositesevolution.com
 

 

Logistical & Linguistic Support in China for Composite Orientated Business Activities

Red Composites are now able to provide our clients with comprehensive assistance in their project-based Chinese business activities.  This can include fixing visit itinerary logistics, scheduling meetings, translation services and accompaniment for an entire visit to China. This flexible service is provided at an attractive cost through Composite orientated and confidentially minded native Chinese speakers. 

Indistinct, secondary advantages result from the freedom to roam potential partners in China, private interpretation of Chinese cultural signals and insight in to the commonly frustrating ‘Chinese only’ conversations.

 

Please contact info@redcomposites.com to confidentially outline your initial Project aims

Website: www.redcomposites.com

 

Amber Composites Receives Sunseeker Supplier Of The Year Award For Technical Innovation

 

Amber Composites announced that they have received The Supplier of the Year Award for Technical Innovation from leading luxury motor yacht manufacturer, Sunseeker International. The award was presented by Sunseeker founder Robert Braithwaite at the Southampton Boat Show and is in recognition of Amber’s development and supply of prepreg material.

 

Amber Composites and Sunseeker International have collaborated on several high-profile projects utilizing prepreg. In 2009, they worked together to create a sledge made from prepreg to support the Help for Heroes Kilimanjaro climb. Building on that success, Amber developed a new resin system for Sunseeker in 2010, Multipreg E520, for a lateral hoop on the flybridge of the Manhattan 73. The hoop provides strength and stiffness at a high point in the superstructure where weight savings is particularly desirable.

 

About Amber Composites
Amber Composites is a manufacturer of composite materials for high-performance, lightweight structures. Amber provides materials and technical expertise to a diverse set of industries including motorsport, automotive, aerospace, communications, marine and wind energy. Amber Composites is an ISO-9001 and ISO-14001 certified company.

 

Website: www.ambercomposites.com

 

Solent Composite Systems Ltd (SCS), manufacturer of ProTek™ composite passive fire and blast protection systems, and Composites UK member has recently secured a number of large contracts for their lightweight protection products in France
and Norway.

 

Consequently the company is about to expand their operations by moving during October 2011 into a larger manufacturing facility purpose-modified to suit their current and future needs.

 

This coincides with a independent recertification audit in order to extend the company’s integrated management system (IMS) to include the new premises, which includes accreditation to ISO 9001 for quality, ISO 14001 for environmental performance and BS EN OHSAS 18001 for health and safety control of its operations.

 

The SCS ProTek™ system meets all current requirements for jet-fire, pool fire and blast protection. ProTek™ enclosures are typically used for ESDV/actuator protection must also withstand wind and wave load acceleration movements under extreme climatic conditions. The high insulation properties of the ProTek™ system ensures minimum temperature rise, thus providing essential integrity of the protected equipment. In addition ProTek™ delivers sound attenuation up to 38dB(A) according to NORSOK R-004.

 

ProTek™ is manufactured from an advanced composite system which is lightweight and has wide design versatility. Being virtually inert, there is zero corrosion risk and outstanding weather resistance, thus offering a maintenance free life for at least 30 years. In addition ProTek™ does not contribute to water or air pollution Fire and blast performance is certified by Lloyds and DNV and will withstand a two hour jet fire test at 0.3 kg /sec gas release, and blast tests up to 1.5 barg.

 

SCS has more than 20 years’ proven track record of providing engineered composite solutions to the energy industry – not only offshore oil and gas, but wind and tidal stream. SCS energy industry expertise coupled with world class Quality, Health and Safety and Environmental compliance to ISO standards, enables it to safely take on major projects and take them thorough to timely and cost effective completion.

 

Website: www.solentcompositesystems.com

 

 

DSM Composite Resins recently made an announcement confirming their intention to cease production within the UK by the end of 2012. We would stress that this should not unduly concern customers. DSM are fully committed to transition as much as possible the current products to other DSM plants within Europe. Although this will undoubtedly lead to some realignment of the DSM product range, at this stage it is too early to be specific, and all efforts will be made to ensure ongoing, reliable service of customers products. Individual customers of any effected materials will be kept informed of any changes as they develop by their Euroresins Territory Sales Manager."

 

"Euroresins UK Ltd is and remains 100% committed in its position as the leading distributer within the UK GRP composites market. Customers can remain confident in our continued quality and ability to serve, as well as our depth of our product range. We continue to offer an extensive range of materials including DSM resins, Bufa resins, gelcoats and bonding paste as well as PPG reinforcements, United Initiator catalyst, SPC release agents, Trident Foams etc, and a wide range of tools and ancillary items. Indeed we have recently added to our active range of products with the introduction of our Machinery Division, offering a wide selection of application machines, (manufactured by BUFAtec), complete with spares and service back-up. These comprise gelcoat spray machine, bonding paste applicators, dosing systems, lamination and injection systems.

 

Website: www.euroresins.com

 

New Autoclave arrives just in time for Alpha Composites

 

Alpha Composites have this week taken delivery of a long awaited new autoclave at their factory unit at Little Balmer, Buckingham, and management breathed a sigh of relief to see the new autoclave installed, as extra manufacturing capacity is needed to cater for a growing order book with defence and aerospace customers.

 

Alpha Composites is established at the forefront in the continuing evolution of composites engineering. As an original equipment manufacturer they offer their customers a complete composite manufacturing process, with the ability to take initial submitted designs through to manufacture of tooling block patterns and shuttering, mould making, component laminating plus trimming and the assembly of complete bonded structures. The success of the company is based on the creation and delivery
of innovative composite design solutions, combined with technological and engineering expertise in qualified growth market sectors.

 

Ian O ‘Dell, Joint Managing Director said: “In 2009 we expanded production facilities into the building adjacent to our main factory – doubling the production capacity and increasing on-site production capability to include an additional curing oven. In 2010 we occupied the premises at Little Balmer and the arrival of the new autoclave provides the opportunity to increase production capacity further and ease our congested order book. This new facility completes another phase in the on-going development at Alpha Composites Ltd., and throughout 2011 we are evaluating opportunities to design and build a completely new premises located within the Buckingham area.”

 

Customers at Alpha Composites have the surety that work undertaken at Alpha Composites is conducted under strict Confidential and Non-Disclosure Agreements and this confidence allied with proven product quality and delivery has been a contributory factor in the steady expansion into new market sectors such as the Defence, Aerospace, Wind Turbine, fixed wing and vertical take-off UAV’s and ROV’s.

 

Since its inception just over 2 years ago, Alpha Composites Ltd has become a supplier to the UK MOD with an Urgent Operational Requirement – the Short Gap Crossing, now in use by UK Forces on the front line in Afghanistan, plus the manufacture of other Defence products, UAV’s, ROV’s and aerospace components.

 

Significantly, Alpha Composites Ltd is a success story in times when other companies have faltered and closed. During the past two years, despite the period of economic ‘downturn’, Alpha Composites Ltd has increased staffing levels, with over 50 employees in the Delta Group. On-going recruitment is generally from within the local area and the company training programmes ensure that all Alpha Composites production trainees and employees are NVQ2 trained to maintain technical excellence and quality standards. Alpha Composites it is an important employer of people from the local Aylesbury Vale and surrounding area – and an increasingly important contributor to the Aylesbury Vale economy.

 

Webiste: www.alphacomposites.co.uk

 

Web Processing (M/C) Ltd and Texkimp Ltd the Perfect Partnership

 

Web Processing (M/C) Ltd based in Whaley Bridge UK are delighted to announce after period of strategic silence, that they have successfully negotiated an eagerly awaited deal that secures the company as the newest addition to the rapidly expanding Cygnet Group of Companies based in Northwich, Cheshire, UK.

 

Web Processing are already well known and respected in the technical textiles arena, and, with the assistance of their sister company Texkimp (and the rest of their new group companies) is sure to become an even more significant force in the textile and composites world. The benefits are obvious to anyone who knows the Cygnet Group and Web Processing is delighted for what lies ahead for the company and for it’s customers whether they be existing or new clients.

 

Web Processing’s forte lies within the specialist traditional textile finishing sector and it provides solutions for clients wishing to add value by coating, laminating, impregnating and flocking. Their recent inclusion into the Cygnet Group provides a firm platform, with almost unlimited resource at their disposal that will allow the company to grow with a new focus in certain strategically targeted areas, this will include a significant increase in the number of staff it has at present by the appointment of new sales, engineering and operation staff and the provision of a magnificent, state of the art, manufacturing and demonstration facility currently scheduled for completion in the latter part of 2012.

Texkimp are a company fo

cused upon the supply of unwinding creels and fibre feeding equipment from package formation, up to the process input. Their main activities service the following areas:-

 

Tyre cord
Poly tapes and monofilaments
High tech fibres that include (Carbon, Aramid, Glass etc)
PAN precursor creels
Package handling equipment
A range of driven systems and over end creels
General spare parts

 

The experience and expertise provided by the two companies and others in the group provide a “one stop solution” for much of what is required by many of their clients. Other group resource includes companies that specialise in the design of bespoke machines and the provision of project and engineering services, machine installations, automation, design of drives and controls, robotics with internal programming expertise, materials handling, a specialist coupling company serving the oil and gas industry, and a recruitment company specialising in high calibre engineering staff.

 

Each company focuses on its own particular area of expertise however the group ethos is to form robust and long term partnerships with the clients its member companies serve.

 

Web Processing’s Managing Director, Barry Goodwin stated “I am passionate and very proud of what this company and my team provide by way of solutions for the clients that we are able to develop relationships with, we are delighted now to be able to call upon Texkimp should we require their services and expertise.  Both companies value greatly the business each and every client provides us, from low cost spares, to more sophisticated high value installations, this, and delivering a project on time, to specification, and at a reasonable price whilst supporting the client is key and is the secret of our success. We are just embarking on a sustained period of rapid growth and investment that will set us up for the next decades and the service we provide today for our clients can only improve in the future”

 

Both companies are present at the ITMA showcasing the innovative equipment they provide - Texkimp are in Hall 3 stand C139 and Web Processing are in Hall 6 Stand B132 each have key staff manning the stands throughout the ITMA

 

Website: www.webprocessing.co.uk
Website: www.texkimp.co.uk
Website: www.cygnet-group.org
 

 

Huntsman Helps Carbon Innovation Achieve Maximum Efficiencies in New Marine Project

Tooling and production materials from Huntsman Advanced Materials have been selected to construct a new One Design carbon racing yacht in a project which sees Huntsman supporting each stage of the project; from design through to the finishing techniques in production.

The ‘CODE8’ is a light displacement, high performance racing yacht.  Designed by America’s Cup yacht designer Andrej Justin and professionally crafted by Carbon Innovation Ltd, the ‘CODE8’ is set to compete in top level local and international regattas.

Carbon Innovation decided to use Huntsman’s production materials after consultations with Farix Ltd, Huntsman’s distributor in Hungary.  The materials were chosen for their toughness, high quality surface finish and dimensional accuracy.  Also, in the case of parts production, they were specifically selected for their heat and chemical resistance properties.

CAD data was initially used to produce a plug of the yacht from a PSFoam substructure and (RenPaste® SV36 / Ren® HV 36) modelling paste.  The parts were then CNC machine milled to create a master model for fast extrusion, exhibiting both low shrinkage and a smooth surface finish.

A high performance gel coat (Resin XD4615 / Ren® HY 5159) was then applied to the master model and a backing layer was built up (using Renlam® CY219/XB5173 in combination with glass fiber) to form the mould for the hull, deck and all other parts.

The hull and deck have been produced from the mould using a hot curing system for vacuum infusion (GL certified, Araldite® LY 1564 / Aradur® 2954) and bonded together with an epoxy adhesive (GL certified, Araldite® 2015) which forms durable, elastomeric joints that are water tight and weather resistant. 

Combining low viscosity with a long pot life at elevated temperatures, the hot curing system offers excellent mechanical, dynamic and thermal properties.  Optimised to provide high Tg, this high temperature resistant system is also suitable for the manufacture of boats finished in dark colours, such as black or dark blue.

For other components, including the mast and rudder, an Araldite® pre-preg system (Araldite® LY 1556 / Aradur® 1573 / Accelerator 1571 / Hardener XB 3403) was selected and used in combination with Carbon Innovation’s self-developed pre-preg machine.  This system has an easy B-staging and GL certification and can also be used for wet lay-up; filament winding and resin transfer moulding.

“Using Huntsman’s products and systems throughout the project has optimised our management time and provided a central expert source of technical know-how and product supply,” said Tamas Simon, Managing Director at Carbon Innovation.

“On a practical level we are realising cost benefits and are on target to meet our time to market objectives, with minimal waste and downtime.  The quality of parts has matched the ambition of our design at every stage.”

The ‘CODE8’ has been built to the highest standards, utilising state-of-the-art construction materials and production technologies comparable with that used in America’s Cup yacht construction and fit out.  Progress through the design, development and production stages was rapid, with the first ‘CODE8’ yacht having taken 4 months to complete. 

The boat will first take to the water to compete in the Keszhely-Kenese, a short handed solo race, on 20th August.  In September, it will compete in both the Centomiglia at Lake Garda on 10th and the TBS cup at Lake Balaton on 23rd.  Following this, on 9th October the ‘CODE8’ is scheduled to compete in the Barcolana. 

Website: www.huntsman.com/advanced_materials
 

 

New Low Energy Milling Technology for GRP and Other Composites

On show at this year’s Composites Engineering Show will be new patented low energy milling technology that is capable of meeting the fine grinding requirements of composites and other hard materials.

Engineering specialist‚ the Gateshead-based International Innovative Technologies (IIT) has pioneered the new technology for the fine grinding of composites, raw materials and minerals into fine powders.

These include GRP and other composite materials as well as aluminium oxide‚ silicon carbide‚ glass and other minerals and aggregates.

Importantly‚ the low energy performance of the new mill has the potential to convert what may currently be regarded as waste material into commercial products for recycling and re-use. This is particularly the case in the GRP industry where IIT has successfully installed a milling plant in an established production facility for the recycling of scrap and waste GRP back into original products.
 

This process involves GRP waste first being converted into flakes using shredding equipment before secondary reduction is carried out in an IIT m-series mill which successfully converts the flakes into a fine powder of generally less than 100 microns for re-use in the primary batch for the manufacture of new GRP products.

Tests and production runs have shown that the inclusion of a percentage of this powdered material back into the primary batch for the re-injection of new products has no detrimental effect on GRP.

Compact and powerful‚ the centrifugal grinding mechanism of the m-series is extremely efficient with the vertical material flow path and special roller assembly ensuring that the force produced is translated into maximum particle grinding power.

The IIT grinding mill and ancillary particle sizing plant are ATEX compliant.

Website: www.iituk.com

 

Aerovac to Take Part in Composites Meetings 2011

 

Richmond Aerovac is pleased to announce that they will be participating in Composites Meetings 2011 at La Cité Nantes Events Center.  This year will see the 3rd international business convention dedicated to composite materials, held on 19th and 20th October.  This B2B event brings together users of composite materials and suppliers of parts and capabilities, and is a must-attend for composite material users involved in supply chain, procurement, engineering and fabrication with applications in aerospace, automotive, construction, medical, rail industry, sail boat construction, shipbuilding and sports and leisure.

 

To learn more about Umeco Composites and Richmond Aerovac’s products, which include all vacuum bagging consumables and innovative product solutions, register online and we’ll see you there!

 

For further information, please contact:

 

Richmond Aerovac UK
Tel: +44 (0) 1274 550500

 

Website: www.umeco.com

 

Accessories for Composite Testing

Instron® systems are used worldwide for testing the mechanical properties of composite materials. With applications including aerospace, automotive and renewable energy, the requirements for accuracy, reliability, and ease of use has never been greater.

Our new range of specialized composite testing fixtures provides full compliance with International and industry standards for a wide range of test requirements to meet the different modes of composite testing including:

• Tensile (ASTM D3039, EN 2561, EN 2597 ISO527-1 and 5)
• Flexure and ILSS Interlaminar Shear (ASTM D2344, EN 2563, EN ISO 14125, EN ISO 14130)Climbing Drum Peel (ASTM D1781)
• IITRI and Celanese Compression (ASTM D3410, ISO14126 Method 1)
• Combined Loading Compression (ASTM D6641)
• Compression After Impact (ASTM D7137, Boeing BSS 7260 and Airbus AITM 1-0010)
• Compression Anti-Buckling (ASTM D695, ASTM D3846, SACMA SRM1-88, BSS 7260)
• Shear (ASTM D4255, ASTM D5379)
• Flatwise Tensile and Shear of Sandwich Core (ASTM C297 and C273)

Many application solutions for composites can be found at Instron testing solutions.

In addition to the dedicated fixtures above, Instron also offer a wide range of hydraulic grip and chamber combinations.

Hydraulic Wedge Grips for Composites Testing

• Tension and compression
• Excellent alignment and repeatability
• High lateral stiffness
• Use very short unsupported gauge lengths (<10 mm) for compression testing
• Extended versions available for use inside temperature chambers
• Control of initial gripping force
• Capacities < 600 kN 

In addition to the mechanical part of testing, it is important to present the results in a professional way and have confidence in the data. This can be done by using any version of our Bluehill® Software

Website: www.instron.com

 

 

Piper Test and Measurement Ltd & Siemens AG
Optimised Design of IPP Drive Support Structure

Company Profile

Piper Test and Measurement manufactures engine test systems incorporating its own range of dynamometers for specialist industries. Their instrumentation is comprehensive and ranges from simple analogue to full computer based data acquisition systems.

Component test systems are designed in close co-operation with the customer. Their knowledge of mechanical, electrical and hydraulic systems enables value for money units to be manufactured at short lead times, whilst close co-operation with engine manufacturers enables the most suitable test schedules to be prepared.

Piper Test and Measurement Ltd’s dynamometer equipment is used by the majority of engine manufacturers, distributors and their dealers. It was Piper’s intimate knowledge of dynamometer and loading systems that convinced Siemens AG to appoint Piper Test and Measurement as a suitable partner in this project.

Background

This case study describes the design and analysis of a support structure for a braking system that was used for a huge flywheel generator. The flywheel generator was designed as a motor generator unit used by the Max-Planck-Institut für Plasmaphysik (IPP) in Garching, Germany, to provide a considerable amount of power for their experiments. IPP is investigating the physical principles underlying a plasma fusion power plant, to produce energy.

Piper Test and Measurement were required to supply a braking system for the flywheel generator. A combination of a hydraulic dynamometer and a water-cooled disc brake was the only possibility as nothing else would have fitted into the building. This braking system allowed the flywheel to come to a standstill in less than ten minutes, without it the generator would have taken a considerable time to slow down and stop. The motor-generator was positioned on a concrete isolation block, connected to the floor of the building by damper elements. As a flexible shaft connection did not exist in the required size through which the new brake could have been connected, the braking system had to somehow be fixed onto the concrete foundation. However, the foundation did not have enough space for the new brake assembly simply to be placed onto it. Therefore, a cantilever supporting structure had to be designed for the braking system, which was to be fixed to the concrete block using some pre-existing holes drilled through the front face of the concrete block. IDAC were required by Piper Test and Measurement to carry out Finite Element Analyses (FEA) to evaluate the design of a support structure for the braking system.

Analysis

The FEA project carried out by IDAC was split into three phases as follows:

Phase 1 - Shape
A topological optimisation was carried out in order to determine a preliminary design of the support frame. This part of the project was carried out using the Shape Optimiser in ANSYS Mechanical. The software approximated the initial structure as a large volume, which was then “eaten away” at locations with low stresses, leaving a “pixelated” representation of the optimised support structure. The graphics to the left (top) show the starting geometry as a large volume and below this, the initial design shape that was predicted by ANSYS can be seen. An envelope of the initial volume was defined to locate the soleplates for the support structure and to define the position of the side arms. The loading consisted of a static load (weight of the components and platform) and a dynamic load (reaction torque applied by the dynamometer and disc brake).

Phase 2 – Sizing & Dimensioning
Using the topologically optimised solution from Phase 1, a design optimisation was carried out in ANSYS Mechanical APDL. A parametric model of beam and shell elements was created and optimised. The sizes and thicknesses of the beams and shells respectively, were defined as design variables and the mass of the structure as the objective function. The natural frequency was defined as a state variable and the mass of the structure as the objective function to ensure that the natural frequencies of the steel support structure avoided the critical resonant frequencies of the concrete foundation block. One of the mode shape plots can be seen in the graphic to the right (top). The design optimisation allowed the design of the support structure to be refined, and the beams and plates to be sized; this was then forwarded to Whittaker Engineering, who would be manufacturing the support structure. Whittaker Engineering made some manufacturing modifications to the supporting structure design and provided IDAC with an Autodesk Inventor model of the structure for further analysis.

Phase 3 – Manufactured Design
This part of the project involved analysis of the Autodesk Inventor model in ANSYS Mechanical. The solid model of beams and shells was meshed with solid elements and then re-analysed to verify the final design of the support structure. The graphics to the right (middle & bottom) show the deformation and von-Mises stress results.

Design Benefit

Carrying out a shape optimisation within ANSYS Mechanical enabled the design of a supporting structure for the 11 tonne brake assembly to be carried out successfully. The analysis provided a design which made use of minimum weight and space, whilst giving a reliable design and a cost saving. The results from the analyses also showed that maximum performance was attained whilst avoiding the modes of resonance of the concrete foundation block.

Eddy Perk, Managing Director of Piper Test & Measurement says: “IDAC were given a number of criteria which were essential for the successful operation of the system. The thoroughness with which they approached this task was without doubt professional and their capability in applying the ANSYS software impressive. This task
would have been both cumbersome and virtually impossible if done without this software. Time and money well spent”.

 

Website: www.idac.co.uk