NOVEMBER/DECEMBER 2023 www.composites.media RECYCLING: UPCYCLING THROUGH SIZING p14 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING SHOW PREVIEW PAGE 28
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Welcome to the Advanced Engineering show edition of Composites in Manufacturing magazine. Held at the NEC, Birmingham on 1-2 November, read all about it in our exclusive show preview starting on page 28. Our show issue features two articles focusing on wind energy, and particularly the repair and recycling of wind turbine blades. Whilst any attempt to meet net-zero goals should be applauded, are we deceiving ourselves by believing in the use of green energies, when in fact all we’re doing is accumulating more waste by using landfills to bury non-biodegradable glass fibre blades? We need to get rid of them completely. There seems to be a pattern emerging around the theme of presenting accurate facts and figures relating to sustainability. Together, national news and social media are often guilty of fuelling a greenwash of misinformation to increase their popularity at the expense of accuracy. For me this mirrors what can sometimes be heard going around the sector, with many conferences invariably focusing on an industry’s standing, the challenges it faces and how it must maintain a competitive edge. A flurry of industry consultants will blow in like the unseasonal weather we’ve been having lately, making predictions on what the sector can expect in the future. There’s also some debate in establishing an even base of agreement on the accuracy of these figures, with some crazy swings between the highest and lowest estimates. Forecasting facts and figures, like the weather, is changeable. It’s not always doom and gloom – more a case of our industry being prepared for anything that is thrown at it. A tad pessimistic perhaps, but we’re in an age where much attention is being paid to a greener future. The irony is that without some serious thought given to recycling, we may not have one. Mike Mike Richardson, Editor Contents... EDITORIAL Editor: Mike Richardson e: editorial@composites-manufacturing.com Deputy Editor: Ed Hill e: ehill@mitpublishing.co.uk Digital content coordinator: Michael Tyrrell e: mtyrrell@mitpublishing.co.uk SALES Business Development Manager: David McCauley T: +44 (0)7557 308369 e: dmc@composites-manufacturing.com Key Account: Andy Morley T: +44 (0)1634 830566 e: sales@composites-manufacturing.com PRODUCTION Production Coordinator: Ewa Hodden e: ehodden@mitpublishing.co.uk T: +44 (0)1634 825703 Art Editor: Sarah Blake e: sblake@mitpublishing.co.uk T: +44 (0)1233 770781 CIRCULATION AND SUBSCRIPTION Circulation: Perception SAS e: cim@mitpublishing.com T: +44 (0)1825 701520 Financial Controller: Valerie Prentice Publisher: Liam McCauley Director: David Rose Published by: MIT Publishing Ltd Featherstone House 375 High Street Rochester, Kent ME1 1DA T: +44 (0)1634 830566 F: +44 (0)1634 408488 www.composites.media Whilst every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they arise. Author’s opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. Copyright: MIT Publishing Ltd 2023 Printers: Pureprint Group Published four times a year, Composites in Manufacturing (CiM) is distributed free of charge to applicants in the UK who meet the publishers’ criteria. Annual Subscriptions are available at £60 for UK and £80 for overseas. Don’t trash the future 4 NEWS SECTOR REPORT 10 At the leading edge of repair – Power generation MATERIALS SPOTLIGHT 13 Finishing trends – Finishing 14 COVER STORY Upcycling through sizing – Recycling 16 Measuring up to aerospace testing – Test & measurement PROCESS SPOTLIGHT 18 Fit for purpose – Filament winding 20 A new era in digital cutting automation – Flatbed cutting 22 Collaboration leads the way – Cutting tools 24 Waterjet cutting keeps drones flying – Waterjet cutting 26 Revolutionising solar car production – Kitting EVENTS 28 A revived revamp for Advanced Engineering – Advanced Engineering show 33 A procession of composites progress – Advanced Engineering show COMPOSITES UK REPORT 38 Providing SME accessibility to large tradeshows – Composites UK NEXT ISSUE: JEC World 2024 show preview, Transport sector report, Materials: Raw & semifinished materials and Pattern & mould, Processes: CNC machining centres and AFP/ATL, Subcontracting solutions THE INSIDE STORY www.composites.media | NOVEMBER/DECEMBER 2023 | 3
4 | NOVEMBER/DECEMBER 2023 | www.composites.media NEWS COMPCUT, the specialist division designing and manufacturing composite cutting and machining solutions, powered by Sharp & Tappin, is continuing to receive widespread acclaim for its groundbreaking advanced composite saws from a leading international composite supplier. Toray Advanced Composites UK has seen significant improvements to its mechanical testing operations since its acquisition of a COMPCUT ACS 600 in November 2022. This mid-range sized COMPCUT machine is equipped with a substantial 600 x 600mm panel size, which enables Toray to effortlessly accommodate large laminate sizes and test specimens. The size of the machine’s operation, in conjunction with a host of additional COMPCUT advantages, has helped to significantly enhance the sample preparation process for this Advanced Composites division of Toray Group. Used daily over the course of eight months, the machine has been instrumental in producing test coupons from a range of materials, including carbon/glass fibre prepreg and Toray’s high performance syntactic materials. Speaking on its reliable service, Toray Advanced Composites’ product development & technical manager, David Jones, said the machine ensured each sample was produced with an excellent surface finish and with a consistent level of accuracy: “The Compcut 600 has been a positive asset to our test specimen preparation. The specimens are repeatedly produced accurately with a smooth edge finish. The clamping system and easy clean down has also saved operating hours compared to our other cutting methods.” COMPCUT has successfully demonstrated its benefits to Jones and his team throughout its initial installation period. “The machine saves time in set-up and clean down,” added Jones. “Specimens are always within expected tolerances. The ACS 600 has enabled a faster turnover of specimens compared to our other cutting equipment and has been easy to train our operatives on.” The ACS 600 comes equipped with a protective, enclosed cutting platform that is standard across all COMPCUT cutting solutions. This provides added safety and protection for the operator while eliminating mess and reducing cleanup, which holds significant advantages for laboratory environments. Jon Small, COMPCUT head of sales, said: “The response we have had from David and his team at Toray Advanced Composites has been fantastic. It is a thrilling testament to the possibilities for not only the ACS 600, but our entire catalogue of COMPCUT advanced composite saws and precision composite routers, that routinely demonstrate the six key attributes that form the COMPCUT promise - safer, cleaner, easier, quicker, cost-effective, and consistently reliable.” British car manufacturer, Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint. The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance. The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalised lacquer, offering a unique aesthetic finish. Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without any technical compromise, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138grams/m2, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers. Marc Cohen, Hypetex CEO, said: “I’m proud that Hypetex has been part of this project to create one of the world’s lightest and fastest production supercars. Our coloured carbon fibre is a perfect match for the sleek design and raw power of the BAC-Mono R.” HYPETEX BRINGS COLOURED DASH TO SUPERCAR www.hypetex.com COMPCUT speeds sample preparation www.compcutacm.com
www.composites.media | NOVEMBER/DECEMBER 2023 | 5 INFINITE POSSIBILITIES. ® BRITISH MADE. WORLD CLASS. Quickgrind’s Fusion range of application-specific tooling has been designed for the flawless machining of composite materials from CFRP to fibreglass and engineered plastics to wood laminates, eliminating disbonds, fibre pullout, splintering and overheating. Our newly developed cutters for epoxy tooling board are extending tool life by 3x over other solid carbide products. Call +44 (0) 1684 294090 to place your order or visit quickgrind.com to find out more. High Technology Composite Cutters 3x extended tool life Quickgrind has been at the forefront of developing and manufacturing tools for the high productivity trimming, milling, routing, drilling and reaming of composite materials for many years. Take its Dagger drills from the company’s Fusion range of composite cutters, used for producing accurate holes without delamination as they exit the hole. For even finer tolerance work the company also offers the Dagger drill/ream. Quickgrind’s R&D team analyses its customers’ manufacturing methods and produces composite cutting tools to reduce the effects of vibration, heat, material build up and tool wear. When approached by a well-known aerospace manufacturer to improve the machining of glass epoxy board, Quickgrind looked at machine set up, stability of workpiece, spindle power and swarf extraction amongst other factors. Using the correct mix of carbide grade, cutting edge geometry, length of flute and reach, coating and by introducing its Amrita anti-vibration technology, the result was a cutting tool that reduced cycle times by 40% and improved tool life by 60%. Tool specifications encompass a range of features and options tailored to meet various machining needs including customisable neck lengths and diameters. Tool shanks comply with DIN and other standards as necessary, ensuring compatibility with various machining setups. Moreover, Fusion tools offer the flexibility of through-tool air blast or minimum quantity lubrication to optimise machining conditions. When specified with chip breaker edges, Fusion composite cutters are designed to effectively manage chip size, making them suitable not only for typical machining but also for cutting model board materials. Depending on the customers’ needs, tools can be configured with the desired number of flutes, helix angle and ballnose end. Additionally, tools are available with straight flutes and right-hand or left-hand helix configurations, enhancing their adaptability to different machining scenarios. The Fusion range has been developed to work with a wide range of materials including CFRP, glass epoxy laminates, sandwich materials, engineered plastics and wood. Their adaptability makes them an ideal choice for various applications such as profile milling, pocket milling, side roughing and helical milling, ensuring efficient and precise machining operations across diverse materials and tasks. Quickgrind unveils Fusion cutter range www.quickgrind.com
NEWS 6 | NOVEMBER/DECEMBER 2023 | www.composites.media Raising the profile of advanced engineering and scientific SMEs We know your industry. We know your target audience. With our marketing knowledge and PR expertise, let us help your business prosper. PR | MARKETING | SOCIAL MEDIA | EVENTS| AWARDS FORENSIC LEAD GENERATION | DESIGN | WEB & SEO When it comes to PR & marketing, let Aro do the heavy lifting. 0117 379 0008 | www.aroprandmarketing.co.uk Composites UK has revealed the shortlist for its 2023 composites industry awards. Due to a phenomenal number of entries, more companies have been shortlisted for an award than ever before. Announced in alphabetical order, the shortlisted entries for each award category are as follows: Innovation in Composite Design: Carbon ThreeSixty, Chemical Processing Services, FAC Technology, National Composites Centre; Innovation in Composite Manufacture: Far-UK, GKN Aerospace, Lineat; Innovation in Composite Materials: PRF Composite Materials, R-Tech Materials, TISICS Metal Composites; Sustainability Award - Circularity: Gen 2 Carbon, Longworth, Qube Buildings; Sustainability Award - Net Zero Initiative: Far-UK, SHD Composite Materials, TISICS Metal Composites; Social Impact: GRP Solutions (outright winner); Employer of the Year: Leybold, R-Tech Materials; Apprentice of the Year: Matthew Sellers (AMRC), Marcus Mullins (Leonardo), Kwaku Adjapong (McLaren Racing); Outstanding Contribution to the Composites Industry Award: Mona Jesri (SM8RT), Paul Beckett (Total Machining Solutions). Whilst the winner of the Social Impact Award is already announced as GRP Solutions, the winners of the remaining categories will be made known at the Awards Dinner on 1st November 2023, taking place at the National Motorcycle Museum. The event coincides with the Advanced Engineering Show at the neighbouring Birmingham NEC. Claire Whysall, marketing and communications manager for Composites UK said: “We were overwhelmed with the number of entries into this year’s awards. They were all really high quality, reflecting on the innovative work happening right now in the UK’s composites industry by amazing people. We are looking forward to the dinner and can’t wait to see everyone there.” The event will be hosted by Composites UK’s sustainability manager, Malcolm Forsyth, and will see the enthralling Richard Noble OBE from ThrustWSH join the event as the after-dinner speaker. COMPOSITES UK REVEALS AWARDS SHORTLIST FOR 2023 https://compositesuk.co.uk Precision diamond tooling specialist, DK Holdings has announced its membership to Composites UK. “We have worked with and supported the traditional and emerging sectors within the composite industry globally since the early days of DK Holdings nearly 65 years ago, manufacturing off-the-shelf and bespoke diamond tooling solutions from within our ISO-accredited production facilities in Kent,” stated company managing director, Andrew Gentle. “Our philosophy has always been to work in partnership with our customers, understanding their requirements and developing tooling solutions to optimise their production processes, as well as utilising our experienced team to assist them with new development projects. Being a member of Composites UK enables us to deepen our knowledge of this innovative, fastpaced sector by working together with our industry peers and specialists.” “We are looking forward to working with our fellow Composite UK members and supporting them as well as sharing exciting projects that we have in the pipeline for 2024.” DK Holdings announces trade body membership www.dk-holdings.co.uk
Book a live cutting demonstration on our stand at the Advanced Engineering Show STAND V150 1st - 2nd November at the NEC in Birmingham Premier’s MiniClave Launching November 1st Demo it at stand S168, Advanced Engineering, NEC Birmingham
Velocity Composites has strengthened its senior team with the appointment of Kevin Hickey as chief operating officer. Hickey rejoins the team at Velocity Composites to help lead its international growth including overseeing the operation of the manufacturing facility in Alabama, US. With more than 40 years’ experience in the aerospace industry, he previously held the position of site leader at the company’s Fareham facility from January 2017 to December 2020. In his new role, Hickey will be responsible for the global operations of Velocity Composites with particular focus on the US site operations in manufacturing, logistics and distribution. “It’s an exciting time to be rejoining Velocity Composites as we grow the business as an international organisation offering efficiencies to our customers wherever they are,” stated Hickey. “We can reduce waste and work sustainably to help them meet their own targets and business aspirations.” VELOCITY STRENGTHENS SENIOR TEAM Solvay has been appointed as primary composite material supplier to BETA Technologies, an electric aviation company based out of Vermont, with an office in Montréal, Canada. Solvay will provide BETA with qualification support and advanced materials for the production of its ALIA CTOL, electric fixed-wing aircraft, and ALIA VTOL, electric vertical take-off and landing aircraft, developed for a variety of applications, including medical, cargo and passenger transportation. Solvay and BETA are collaborating to select and qualify a tailored suite of materials from Solvay’s broad portfolio to meet the rigorous performance and rate demands of the Advanced Air Mobility (AAM) market. Composites and specialty polymers will be used for primary and secondary structures, as well as non-structural parts, combining multifunctional integration with high strength and low weight, as well as electromagnetic interference and lightning protection. www.solvay.com NEWS www.velocity-composites.com www.shimadzu.co.uk/irxross Top of its class in sensitivity with an S/N ratio of 55,000:1. High Speed measurement of 20 times per second with optional rapid scan software. Quick-click starting and easy navigation with IR Pilot™. The IRXross creates a new concept for infrared spectroscopy. It offers the optimal solution for a new era with diverse application requirements. Performance x Operability New IRXross: Learn more about the best performance at best price! Solvay forms AAM partnership
www.composites.media | NOVEMBER/DECEMBER 2023 | 9 Fibre Extrusion Technology (FET) of Leeds is celebrating a year of achievements since its new Fibre Development Centre was first opened. This period has shown a marked acceleration in the number of client technical trials conducted, involving the ever-increasing development of new polymers. “In the last year we have supported more than 35 clients to conduct trials, many of which have gone on to conduct further trials or place orders for equipment,” explained FET’s research & development manager, Dr Jonny Hunter. “Over these 12 months, interest has ranged significantly from massive multinational companies to start-ups and spin-out companies. It is particularly encouraging that an ever-increasing proportion of new polymer trials relate to sustainable fibres, with more than 25 polymers now being from a sustainable source.” With more new trials booked for the rest of the year and well into 2024, it is expected that many more cutting-edge new polymers will be developed, with sustainable fibres leading the way. FET lauds new development centre The unique ANGOS ARG-B 200 is the rst battery-powered grinding tool from Mirka. The user-friendly ergonomic design gives an excellent balance to the tool and the variable speed control trigger, gives the user an optimal speed control while working. For further information or to arrange a demonstration, please contact Customer Services on 01908 866100. Cordless Grinder Mirka® ANGOS Dedicated to the nish. Find out more at www.mirka.co.uk www.fetuk.com.com INTERTRONICS SECURES UK SCIGRIP DISTRIBUTION Adhesives supplier, Intertronics has partnered with Scigrip to distribute its methyl methacrylate structural adhesives (MMAs) in the UK. MMAs are fast curing, two-part adhesives that cure on mix at room temperature to form resilient bonds. They are ideal for structural bonding of metals, plastics, and composites in industries like marine, transportation, rail, automotive, and many others. “Scigrip has an established position in the marketplace, a broad existing range, and continued product development, so they were an attractive prospect for us when we were looking for a manufacturer of MMA structural adhesives to fill out our portfolio,” explained Intertronics’ chief commercial officer, Ben Swanson. www.intertronics.co.uk
10 | NOVEMBER/DECEMBER 2023 | www.composites.media SECTOR REPORT: POWER GENERATION here has been considerable growth in the wind power industry over the past few years. However, further exponential growth of the industry is required in order to ensure that the net-zero by 2050 pathway - as outlined in the Paris Agreement - is successfully reached. In order to support this seismic growth, polymeric repair and protection technology has an important part to play. Designed to safeguard the integrity of wind turbine blade leading edges for the long term, this technology plays a critical role in supporting this burgeoning industry. According to the International Energy Association’s (IEA) Wind Electricity Tracking Report (September 2022): “In 2021 wind electricity generation increased by a record 273TWh (up 17%). This was 55% higher growth than that achieved in 2020 and was the highest among all renewable power technologies.” While the industry has undoubtedly experienced impressive levels of growth in these years, according to the IEA, wind electricity generation needs to reach four times the record levels set in 2020 by 2030. The Report said: “Our pathway calls for scaling up solar and wind rapidly this decade, reaching annual additions of […] 390GW of wind by 2030”. How is the Scale-Up of the Wind Industry Being Financed? According to the IEA’s Report: “Policy support remains the principal driver of wind deployment in the majority of the world.” Indeed, over the past few years, several policies have been launched that are designed to drive forward the roll-out of renewables. For example, in August 2022, the US brought in the Inflation Reduction Act (IRA) which includes $369 billion of investment, in the European Commission’s Green Deal Industrial Plan, $270 billion was pledged, and since the UK government’s Ten Point Plan was launched in November 2020, over £26 billion of government capital investment has been mobilised. A material whirl Given the critical role wind power plays in the transition to a net-zero future, as well as the significant amount of capital being invested into the renewables industry, the wind power sector is poised to experience considerable exponential growth in the upcoming decades. In order to support this growth, polymeric technology plays a significant role when it comes to maintaining the operational efficiency of the rapidly expanding fleets of wind turbines. Polymeric systems, such as the rebuild, blade filler material, Belzona 5711 and the cartridge-applied leading edge protection coating, Belzona 5721, are specially designed to repair damaged leading edges and protect them against rain erosion and impact damage for the long term. In addition to the performance capabilities of these systems, maintenance engineers are investing in this technology due to the simple, in-situ application method and fast cure times the cold-curing systems facilitate. In turn, this helps to keep downtime to a minimum, and allows Chloe Hirst, senior copywriter at Belzona, the polymer repair composites and industrial protective coatings specialists, examines the role of polymeric technology in the burgeoning wind power industry. At the leading edge of repair T Above Leading edge damaged by erosion
Left Surface preparation using an orbital sander www.belzona.com We are extremely satisfied with the results achieved by Belzona's leading edge repair and protection system Tool-Temp ensures that your processing facilities are kept at the ideal temperature – o ering over 60 standard models and enough individual solutions to satisfy any special requirements you may have. Main features of our new MATIC temperature control units Simple operation Modular Control that is easily expandable Preset actions and easily configurable recipes Anticipatory behavior & predictive maintenance Connectivity Energy e icient control Please contact us on 01933 442 623 or info@tool-temp.net to speak with a member of the Team. 01933 442 623 www.tool-temp.net Swiss Made Experienced in delivering the pe ect temperature the turbine to be returned to service in the same day. Belzona 5711 can be directly overcoated with Belzona 5721 in as little as 30 minutes at 20°C/68°F without the need for any additional surface preparation. At the same temperature, Belzona 5721 will be fully cured within five hours. Belzona successfully addressed the wind turbine blade damage issue at Electricity Generating Authority of Thailand’s (EGAT) Khao Yai Thiang Windfarm in Thailand. The windfarm features wind turbines with 40m-long blades. During routine inspection, evidence of damage measuring 300cm x 14cm x 2mm on the leading edge of one of the blades was discovered. Representatives from the 35-year-old Belzona Authorised Distributorship, Pan Mechanic Engineering, recommended the solvent-free, two-part repair paste, Belzona 5711 to reconstruct the damaged area on the blades, followed by the high-performance coating, Belzona 5721, to overcoat the area. Application procedure The application procedure involved surface preparation using an orbital sander, followed by the direct application of approximately 1.4kg of Belzona 5711 from a self-mixing cartridge onto the blade. The repair area was contoured using a piece of Belzona mixing board. After a two-hour curing period, a visual inspection was conducted to ensure the application's readiness for overcoating with approximately 3.5kg of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure. The blade was back in service 24 hours later. EGAT's technicians were trained at the Belzona Asia Pacific facility to perform the application, with two representatives from Belzona's Technical Service Department present on site to observe and provide guidance. Commenting on the application, an EGAT representative said: “We are extremely satisfied with the results achieved by Belzona's leading edge repair and protection system. The application procedure was very simple, and could be carried out quickly, which ensured that downtime was kept to a minimum. We plan to place an order for more Belzona 5711 and Belzona 5721.” In order to support the seismic growth of the wind power sector, polymeric technology, such as Belzona 5711 and Belzona 5721, plays a critical role. By safeguarding the integrity of wind turbine blades, this helps to keep windfarms functioning at their optimum efficiency, which in turn, supports a net-zero by 2050 pathway for the planet.
Prevention of costly collisions and accurate calculation of job lengths are just two of the benefits of digital twin simulation - available to CNC operations via Biesse’s B_SOLID software. Software is often overlooked as a way of driving efficiencies and reducing CNC processing errors. This is mainly because many manufacturers have experienced the limitations of manual coordinate-based software, whose lack of 3D functionality precludes five-axis simulation. A sharper simulation tool However, in recent years, software has advanced significantly, opening up new opportunities for a value-driven approach to CNC software development. Biesse has harnessed these advancements in the shape of its B_SOLID software, which allows machining operations to create a digital twin simulation of the CNC process. With B_SOLID, powerful processing, sophisticated 3D visuals and machine learning capabilities combine to elevate machine software functionality to a new plane. What does B_SOLID actually do? B-SOLID gives users a unique view into their CNC machine by creating a digital twin - a virtual replica of their machine. Working on the machine’s control panel or on a remote PC, the user can use B_SOLID to design a machining programme and then run a rapid and realistic 3D simulation - de-risking the project by verifying the feasibility of the intended tool path, machining speed and tool selection, and giving an accurate estimate of job completion time. Collision Control: accident prevention Unfortunately, clashes between the machine head and worktable can happen, and they have costly consequences - often resulting in components having to be replaced and damage to the operating unit itself. Historically, to safeguard against collisions, CNC users have run the programme very slowly using a controller - however, this is less than ideal as it eats into valuable machining time. B_SOLID’s Collision Control feature, which allows users to run the programme in a virtual environment, is the solution to this issue. A collision check carried out in an office setting will highlight any contact between machine parts, enabling the user to correct any errors and amend the programme without any actual damage being inflicted. The simulation is able to calculate whether a collision will occur is because the virtual machine is a mirror image of the actual machine - right down to the tooling profiles and axis movements. The sophisticated tool visualisation functionality within B_SOLID is key to this feature and users can build a visual profile of every tool and aggregate that is available on their machine. Job length calculator: assisting scheduling, staffing and costing Simulation is not only handy when it comes to preventing collisions, it also means CNC users can calculate exactly how much time will be needed to carry out the required machining operations. This knowledge is extremely useful for pricing purposes, for example if a manufacturer knows exactly how a long it will take to machine the parts for an individual job, they can use this as the basis for their costing process. This feature is also helpful when planning staffing and scheduling jobs. Within B_SOLID it is possible to create a ‘work list’ of jobs for a particular machine and the software will calculate how long it will take to run this list of programmes. With previous generation software, it wasn’t possible to calculate job lengths to the same degree of accuracy because simulations were only able to show the machining cycle. The simulation that can be performed via B_SOLID is far more advanced, taking into account variables such as ramp up and ramp down speeds as well as tool changes, to emulate a real-life machining operation and build an accurate picture of overall job time. How can I get B_SOLID? Part of Biesse’s B_SUITE range of advanced software solutions, B_SOLID is supplied as standard with all Rover CNC machines. ADVERTORIAL Digital twin simulation software delivers hard benefits to CNC users Contact us if you would like to find out more: +44 1327 300366 | https://www.biesse.com/uk/advanced-materials
WELCOME www.composites.media | NOVEMBER/DECEMBER 2023 | 13 MATERIALS SPOTLIGHT: FINISHING www.mirka.co.uk Scan here for more Mirka articles ithin the composites industry, abrasives play a pivotal role in various processes, contributing directly to quality of the end product. As the demand for lightweight and durable structures continues to rise across industries like aerospace, automotive, and construction, the use of our innovative abrasive and tooling solutions become increasingly indispensable. There is also a slow but concerted move towards automation for composite finishing. This move is happening because businesses are slowly starting to understand and see the benefits in terms of production output and overall efficiency that automation can bring. Once automation becomes the norm, we will see an increase in the use of AI and optical systems that will make bespoke items made through automation easier, as there will be less need to create bespoke programmes for the job, as the AI will constantly be learning and creating relevant programs and moves to do the job. In addition, automation will lead to a reduction in production times that will, in turn, result in an increase in output as well as the quality of the end product. From a business perspective, companies are looking for providers that offer a full service rather than one aspect such as training or abrasives. At Mirka, we provide the whole package by working closely with customers to understand their tooling and abrasive requirements as well as their processes, and we regularly audit their operations to help them plus keep them updated with product innovation. Doing this ensures we can provide the right products so that everything is optimised, which helps increase the efficiency of their processes, in turn, improving their production levels, and our team of experienced technical experts provides ongoing support and training. There is also a focus on health and safety and businesses are recognising the importance of dust-free sanding and a dustfree workspace. To achieve this, businesses are investing in suitable mobile extraction systems. This investment is not a short-term injection of the business’ cash, it should be viewed as a long-term commitment so that it can provide an effective solution for a cleaner workspace, a reduction in prepping and tidying up at the end of the day, and the potential for dust contamination of other tools and surfaces. This investment also ensures the businesses are HSE compliant when it comes to dust in the workplace and takes away the potential citations from HSE as well. Overall, there is going to be evolution and trends that hit the market and the way we will stay at the forefront of the market is through constant communication with the end user to ensure they have the right tools, abrasives and processes to meet their requirements in the short, medium and long term. Above Mirka regularly audits its operations to keep customers updated with product innovations Composite finishing is constantly evolving and there are several trends that Mirka UK and its team of technical experts are seeing on the ground. With this in mind, Composites in Manufacturing met with Chris Brook, business sector manager, transport & industry for Mirka UK to find out more about a few of them. W Finishing trends Below Chris Brook, business sector manager, transport & industry for Mirka UK
14 | NOVEMBER/DECEMBER 2023 | www.composites.media MATERIALS SPOTLIGHT: RECYCLING hilst the energy industry heads towards decarbonisation, it’s easy to overlook the environmental impacts that decommissioned wind turbine blades leave behind. Predominantly made of glass fibre, the materials secondary use is currently limited. Separating the glass from the other materials in the blades make-up (wood, aluminium, carbon fibre, etc) is uneconomical as the cost of virgin glass is relatively inexpensive – circa €2 per kilo. Unless there is legislation to dictate the use of recycled glass fibre (rec-glass), then the business case for the material isn’t currently viable. Whilst the industry is concentrating on recycling the known and commercially viable materials in the makeup of the blades, the non-biodegradable glass fibre is being buried. This situation cannot continue. A UK consortium led by B&M Longworth with partners from Ford Motor Company, Gestamp, GEN2PLANK, EMS-Grivory and academic partners from The Welding Institute (TWI) and Brunel University London (BUL) are engaged in a project part funded by Innovate UK to investigate true upcycling of glass fibre to deliver a genuine viable material with high potential secondary use. Accentuate the positive Called the EMPHASIZING project, the aim is to develop a material with superior mechanical properties to virgin glass, but at a price point lower than carbon fibre – providing a viable, commercially acceptable material that can bridge the gap between glass and carbon fibres. Each blade will be chopped to a size that is commercially acceptable to the secondary use and put through the ‘pressolysis’ process developed and patented worldwide by B&M Longworth. This process removes the resin using superheated steam that undergoes compression and decompression cycles to strip the resin from the fibre. Unlike solvolysis or pyrolysis, pressolysis does not interact with the fibre in any way, thus leaving a pristine fibre. The resin is also recoverable during this process but is not the subject of this project – but is being explored through separate R&D projects. Crucially, the stripping of the resin from the fibre also removes its sizing which allows the upcycling of the fibre as the secondary process. ‘Sizing’ is the term that describes the thin, homogenous coating applied to the surface of fibres during the manufacturing process to protect the filaments during handling, and processing, and also during Above The nonbiodegradable glass fibre elements of wind turbine blades are being buried in landfills Described as Enhancing Material Properties of Recycled Glass Fibres Through Sizing, the EMPHASIZING project targets the wind energy-to-automotive sectors to address the challenge of recycling composite structures currently landfilled or incinerated. Composites UK’s chairman, Dr Alan Banks reports. W Below Dr Alan Banks, chairman of Composites UK Upcycling through sizing
www.composites.media | NOVEMBER/DECEMBER 2023 | 15 www.compositesuk.co.uk We live in a world of unprecedented climate change and it is the responsibility of the industry to ensure that we can find ways of using discarded materials responsibly in a way that enhances the business case Scan here for more Composites UK articles subsequent compounding to promote adhesion in the composite processing. The project will take advantage of the sizing removal during the pressolysis process to allow re-sizing of the recovered material. To upscale and improve the mechanical properties the sizing agent to be applied will be graphene. Graphene is a nanomaterial that is 2D single-layer graphite and is the strongest material known to man. The project will determine the effects of graphene sizing on the mechanical properties of the glass fibre, as well as the cost equations of making the material viable for commercial use. The belief among the consortium is that the mechanical properties will be at around the mid-point of glass and carbon fibre with a price point more towards virgin glass fibre. Graphene was selected as the sizing agent for the project due to its versatility and suitability to upscale glass fibre. Graphene in isolation is a very expensive material to manufacture. However, the volume of graphene required compared to the material substrate is approximately 0.5%; thus making rec-glass affordable. There are many ways of producing graphene from chemical vapour deposition, flash Joule heating, laser induced graphene etc. Whilst the production method isn’t important for the purposes of this research project, the work packages undertaken will include a full lifecycle analysis and so the flash Joule heating method will be considered. ‘Flash Graphene’ is generated by heating of any carbon element to 3,000°C via an electrical impulse. All of the non-carbon elements are ‘sublimed’ out leaving graphene as the only material left in the chamber. This process leaves the graphene in a non-stacked (turbostratic) state for ease of dispersion. The pressolysis process will be used to separate the fibre as stated. Pressolysis has the advantage over more traditional processes in that it leaves the fibres undamaged and is environmentally friendly. Pressolysis has been used previously on the Innovate UK CHASSIS project and has been proven to recover all of the material to the same standard as its virgin form. Pressolysis is alone in being the only process capable of recovering all of the material entered into the decompression chamber – thus the resin and any other materials present in the material makeup will also be recovered and cleaned (metallics, other fibres, etc). Incinerate to innovate These can then be recycled via their usual processes (remelting, etc). The advantages are clear in that these other materials that could be considered as contaminants, are not only unreactive to the main substrate being recovered, but their own recycling credentials are unaffected by the process. This means that to a certain extent, design for disassembly for fibrous elements can be largely ignored. The pressolysis process, compared to more traditional mechanical and thermo/chemical methods is explained below. As well as determining the material characteristics of graphene sized glass fibre, a suspension component will be made and tested against its metallic counterpart to assess its suitability for structural parts and to correlate against the CAE predictions. The final element of the project will be to understand the lifecycle analysis for Scopes 1 and 2 – material production and manufacturing phase – as well as Scope 3 for the weight reduction of the component on the vehicle in the use phase. The Scope 1 data will include the CO2 output from the pressolysis process to ensure the full emissions are taken into account. Due to finish in October 2024, the aims of the project are clear and will ensure that there is a known business case for utilising upcycled glass fibre. We live in a world of unprecedented climate change and it is the responsibility of the industry to ensure that we can find ways of using discarded materials responsibly in a way that enhances the business case. Once there is legislation to prevent glass fibre going into landfill, the whole of the industry will be obliged to recycle at any cost which is potentially damaging to the existing supply chain. Avoiding this scenario is where the EMPHASIZING project comes into its own. Enhancing material properties of recycled glass fibre through sizing will change the way industry approaches recycled materials. Below A diagram demonstrating the pressolysis process
16 | NOVEMBER/DECEMBER 2023 | www.composites.media MATERIALS SPOTLIGHT: TEST & MEASUREMENT ince the mechanical response of fibrereinforced polymer matrix composites is strongly affected by temperature, composites used in aerospace structures need to be tested at low and elevated temperatures. In addition, moisture uptake in a composite material over the lifetime of a composite structure is known to have a detrimental effect on the mechanical behaviour and material properties. Therefore, standardised static testing needs to be done to obtain the mechanical response of the composite lamina and for multidirectional laminates at different temperature and moisture levels: -54°C cold temperature dry (CTD), +93°C elevated temperature dry (ETD), +93°C elevated temperature wet (ETW) and +121°C elevated temperature wet (ETW). This covers the temperature range from low temperatures during flight at cruising altitudes to elevated temperatures on the ground in hot climates. For the wet testing condition, the test coupons are conditioned for several weeks until the desired moisture state in the material is reached. These moisture conditioned samples are then tested at the desired temperature using a static testing machine incorporating a temperature chamber. Typical static tests done on the lamina level are: unnotched tension and compression, in-plane shear, or short beam shear strength. Typical static tests on the laminate level are: unnotched tension and compression, open hole tension and compression, filled hole tension and compression, short beam shear strength, pin bearing, curved beam strength or compression after impact. In both cases, this includes only the most common methods, while several other static test methods are carried out as well. While the vast majority of coupon testing for composite materials is done under static loading conditions, the fatigue response of structural laminates is also evaluated using for example unnotched tension, open hole and filled hole tension and compression, short beam shear strength or compression after impact test methods. Left ZwickRoell servohydraulic testing machine HC100 Compact for fatigue testing of composite and metal materials When it comes to testing the types of fibre-reinforced polymer matrix composites used in the aerospace sector, Zwick says its static and dynamic test equipment measures up. S Above ZwickRoell noncontact optical strain measurement system videoXtens biax 2-150HP Measuring up to aerospace testing
www.composites.media | NOVEMBER/DECEMBER 2023 | 17 www.zwickroell.com Scan here for more Zwick articles Depending on the expected maximum load, the static tests are done on either a 100kN or 250kN testing machine with suitable grips for the tension type specimens while making sure that other test fixtures can be mounted as well. For Nadcap accredited testing laboratories, it is crucial to verify correct alignment or the specimen grips. In this case the testing machine should be equipped with a mechanical alignment unit to be able to correct any misalignment in the load chain. The alignment device is mounted between the load cell and the hydraulic unit of the lower hydraulic grips. Temperature extremes To be able to perform tests at low and high temperatures, the testing machine can be equipped with a temperature chamber covering a temperature range from -80°C to +250°C or -80° to +360°C. A 360°C temperature chamber allows testing well beyond the above mentioned temperature range, which today is required for the development of new composite materials systems that will be exposed to higher temperatures, e.g., near engine exhausts. A major challenge at low and elevated temperature testing is accurate and highresolution strain measurement, which needs to be done directly on the tensile specimen, using contact or non-contact technologies. While the use of strain gauges, bonded to the specimen for axial or transverse strain measurement, has been an established method for decades and is still the standard method for unnotched compression testing, it is also costly and time-consuming. With the increasing use of thermoplastic composites in aerospace composite structures, it can be challenging for some thermoplastic matrix systems to bond a strain gauge to the composite specimen. Contacting clip-on extensometers are an economic alternative, but they can be damaged if used until ultimate failure, particularly for tensile specimens with explosive failure modes. Automatic sensor-arm extensometers can be employed until ultimate failure and can be used for non-ambient temperature testing in a temperature chamber as well. Non-contact optical strain measurement using a video extensometer allows accurate and high-resolution axial and transverse strain measurement over the entire temperature range from -80°C to +360°C and is thus the most versatile strain measurement system for composites over a wide temperature range. The ZwickRoell videoXtens biax 2-150 HP was specifically developed for the testing needs of composites. For many composite material systems and particularly for carbon fibre-reinforced plastics, no further specimen preparation for strain measurement is needed since it uses the natural surface pattern of the specimen to set the gauge marks. For flexure testing, a mechanical plunger is available, which extends the use of the videoXtens to flexural testing as well. Innovation beats vibration Considering fatigue of materials used in aircraft structures is important due to intense vibrations during take-off and landing, engine vibrations or turbulent flight conditions. Wing structures and the materials used in it accumulate a large number of load cycles over the lifetime of an aircraft, from when the aircraft is on the ground and the wing is pulled down by gravitational forces, to when the wings bend upwards from aerodynamic forces during flight. While the importance of fatigue testing increases when moving up in the testing pyramid from the coupon test level with many standardised test methods to structural elements, substructures all the way to the full structural level, fatigue testing of materials on the coupon level is important to obtain data for fatigue tolerant design or lifetime predictions. For dynamic materials testing, servo-hydraulic testing machines are common, since they are most versatile when it comes to load range and testing frequencies. If needed they can also be used for static testing, whereas they do not offer the simplicity of setting up very different types of static test methods as is possible for example with an electromechanical testing machine (see above static modular testing machine). For the load range of 100kN, typically used for fatigue testing of metals and composite materials on the coupon level, ZwickRoell has developed a compact dynamic testing machine with integrated hydraulic power pack. The compact design makes the machine independent from a centralised hydraulic supply, has a lower footprint compared to when a separate hydraulic power pack is placed next to the machine and operates at a very acceptable noise level of <58dB. An integrated cooling system prevents heating of the laboratory and thus a standard laboratory climate is unaffected. The mechanical testing of composite materials is a complex topic, involving a range of test configurations, a wide selection of recognised testing standards and frequently the need to test in a variety of different environments. The availability of well-aligned test machines and gripping arrangements, advanced technology extensometers, interchangeable test fixtures and intuitive testing software, facilitates the mechanical testing requirements demanded by R&D, and routine quality assurance. Above ZwickRoell 100kN or 250kN modular static testing machine for ambient and nonambient testing of composites
18 | NOVEMBER/DECEMBER 2023 | www.composites.media PROCESS SPOTLIGHT: FILAMENT WINDING ith the growing need for automated production systems, CompoTech has expanded its business to offer custom-built ‘turnkey’ automated fibre winding and filament placement machines with a fully-integrated robot arm. The company says the incorporation of proprietary advanced winding technologies in its automated machines opens new possibilities for producing carbon fibre (CF) components. A custom-built automated fibre winding and laying machine project, now installed and commissioned by CompoTech, is being used to develop a new lightweight, high strength CF epoxy composite Euro pallet. CompoTech’s automated robot winding machine was commissioned by a leading logistics company as part of ongoing investments to improve the sustainability of the business. The pallet - also developed by CompoTech - is replacing heavier metal pallets to reduce transportation costs and the carbon footprint of future deliveries. The design of the bespoke automated winding pallet production machine includes a FANUC 6-axis robot with a specially designed ‘end of arm’ fibre delivery head tooling. The robot arm also provides automated tool changes and part loading/unloading. The capabilities of the new automated CF pallet making machine includes both CompoTech’s proprietary axial fibre winding technology and its Integrated Loop Technology which produces fixture-free joints. Both technologies were showcased at the recent JEC World exhibition. All advanced winding machines produced by CompoTech are custom-built to meet individual customer needs and specifications. Individual machines are based on a standard platform. To meet specific customer requirements, automated production options available include Compo FixTool - fixed spindle and tailstock, Compo AdapTool - automatic tool length control up to 3m and Compo LinAx - for larger parts up to 12m, robot mounted on linear axis rails. CompoTech turnkey winding machines include as standard, an integrated FANUC 6-axis robot arm, along with in-house developed ‘Shneg’ fibre placement and winding software that controls the robot arm and winding mandrel. The software converts a design specification into a production programme to precision manufacture a CF component. Standard program preparation winding codes for producing common types of products, such as round tubes, beams and n-edge profiles, come with all machines; the codes provided cover the key production parameters, including diameter, length, and number of pins, sides and spindles, making it easy to either program a new product or to make program adjustments to an existing component. The standard production program codes provided by CompoTech include: Winding of axis-oriented layers; Above CompoTech’s automated CF winding machine with integrated FANUC 6-axis robot arm CompoTech says its custom-built advanced winding technology machines are helping to open up new possibilities for industrial composite components. W Fit for purpose
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