composites | Processing
Right: Sumi- tomo SHI Demag
demonstrated its composite
capabilities at Fakuma with
this nutcracker exhibit
significantly improve the mechanical properties. By using the FiberForm process it is possible not only to replace metal parts, but plastic ones also. “An example of this was an airbag housing developed in conjunction with Lanxess, Siebenwurst and Takata. The standard part made of glass fibre reinforced polyamide had a wall thickness of 3mm. By using the FiberForm process the 3mm wall could be replaced by a 0.5mm composite sheet, which offered the same mechanical properties,” he says. Schierl says the FiberForm process is ideal for
creating parts that are subject to high tensile forces due to the continuous fibre reinforcement in the composite sheet. “Furthermore, holes can be formed,” he adds. “This leads to improved load application in comparison with drilling, because the fibres are not damaged.” Applications are not only focused on the automotive
Below: Arburg’s long fibre direct injection
technology adds fibre
reinforcement into the liquid melt via a side feeder on the injection unit and was used to mould this automotive pedal (centre right)
sector. The FiberForm process was used successfully to manufacture a multifunctional stringer for a touring ski binding for Marker of Germany. “There are a number of advantages that FiberForm has delivered for this ski binding,” says Schierl. “These include high strength and stiffness, as well as an injection moulded connection for a bolt and a thermoformed bead that provides improved mechanical properties. Other features that can be integrated include the size adjustment for the length of the boot, ribs and screw bosses. In addition, the edge of the composite sheet can be over-moulded with plastic to protect the open fibre ends from moisture.”
Integrated functions Sumitomo (SHI) Demag says it is also investigating thermo- plastic composite processing techniques to achieve savings
through the production of functionally integrated components. The company recently demonstrated a
space-saving, compact production
cell around a 210 tonne Systec Servo 210-430 machine equipped with the company’s energy saving activeDrive servo-hydraulic drive
system. It was demonstrated at the Fakuma fair in Germany in October last year producing a hybrid composite nutcracker. The process starts with the pre-heating of an organic
fibre reinforced sheet which is then inserted into the injection mould. The mould is designed to form the sheet as it closes and the formed sheet is then back injection moulded with polypropylene to create a honeycomb reinforcing structure. A metal insert placed in the mould tool as part of the process provides the hinge mechanism and gripping edge for the completed nutcracker. The complete assembly is achieved in the production cell. The result is a lightweight hybrid component with the required stiffness to facilitate the high forces required for the application. Meanwhile, Victrex collaborated with US-based
Tri-Mack Plastics Manufacturing Corporation to develop a new PAEK-based polymer/hybrid moulding technol- ogy. The development means it is now possible to over-mould a PAEK-based composite sheet with fibre-reinforced Victrex PEEK injection moulding materials. According to Victrex, stronger, lower-cost components that are up to 60% lighter than typical metal and thermoset systems can now be designed. The two companies have engineered an aerospace
bracket using the new polymer/production technique. Commercial aircraft require thousands of such brackets and a significant weight saving could be realised if traditional metal types can be replaced with plastic ones. As well as the weight saving compared to stainless steel and titanium, the hybrid-moulded Victrex PAEK-based composite bracket is able to offer equivalent or better mechanical properties such
as strength, stiffness and fatigue.
LFT developments Arburg demonstrated its capabilities in long-fibre direct injection moulding by producing a high strength lightweight pedal for the automotive sector on its stand at the Fakuma fair in Germany last year. Using a 400 tonne Allrounder 820 S with energy saving servo-hy- draulic system, it claimed that material costs could be reduced by more than 50% by using its direct technol-
22 INJECTION WORLD | January/February 2015
www.injectionworld.com
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