COMPOSITES
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Weight can
be reduced by 70% compared to bionic optimised aluminium parts. It is a fully digital process following the bionic design principles of “form follows force”. xFKin3D is characterised by a number of technical features. First is its high
Homogeneous impregnation of a 12k carbon fibre impregnated at 500 mm/s
geometric flexibility (e.g. bionic design), followed by its optimised bionic topography (the fibre design is based on load direction). Other notable features include force and tension being optimised (fibre strength/ direction according to load), and definable/ adjustable strength and stiffness. It features multi-axial load capacity (tension/ compression, bending, torsion) and is also material-optimised/resources friendly (almost any offcut). A final noteworthy feature is the integration of functions in the component, bringing the component to an intelligent “5D” component. In terms of stiffness and especially
tensile strength, it is not possible to build
“lighter” because “only” as many fibres as necessary are used to fulfil the requirements. Terefore, we speak of an additive manufacturing process of ultra-light construction. “Industry 4.0” is on many people’s lips and is understood as the digitalisation of industry. Te targeted networking of industrial structures in an effective networking of efficient software applications is of importance here - i.e. the process from the idea and concept through simulative development and testing to the final production of the component. Tis is where xFKin3D process technology comes in for ultra-lightweight
construction, as the product creation process can be accelerated with this innovative method. Here, calculation and simulation determine the entire subsequent product creation process – the process technology is de facto calculation/simulation-driven, based on the principle “form follows force”. Terefore, we also speak of a “full digital process chain”.
Claude Maack is managing director of Gradel.
www.gradel.lu
COMPOSITE MATERIALS HELP RACING TEAM M
otor racing has always been at the forefront of R&D as every team
looks to shed precious seconds per lap. To encourage automotive engineers of the future, Formula SAE is a global student competition that pits a variety of university teams against each other to develop small, Formula- style race cars. When the racing department at Italian university Politecnico di Milano, Dynamis PRC, was looking to improve the performance of its car’s steering column and suspensions, it partnered with Exel Composites. Dynamis designs and builds formula- style vehicles to compete in the Formula SAE. After a reasonably successful year in 2018, when the team secured top 10 finishes in all its competitions, Dynamis needed to push the following year’s car even further.
fibre was a real breakthrough for reducing the weight of the driving column,” said Vezzoli. “We were able to shed 15kg of weight, which helped shave two seconds off our lap time.” With the carbon fibre pieces
“We had finished a successful year, but knew that our vehicle could perform better,” explains Andrea Vezzoli, technical director at Dynamis. “We had two main objectives: to reduce the car’s weight and to improve the suspension.”
Singling out the steering column as the main area for weight reduction, Dynamis began searching for new materials. After reviewing the focus areas with the racing team, Exel Composites suggested a variety of carbon fibre tubes. “Using carbon
installed, Dynamis took the car to four Formula SAE races. The first race took place in Holland, where the team won overall. Returning to Italy for the third race, Dynamis
saw another victory. Held in Germany, the homeland of many of the world’s largest car manufacturers, the final race was the toughest. Yet even against some of the most competitive teams in the world, Dynamis achieved a strong third-place position, making the season one of its most successful to date. l
For more information visit
www.excelcomposites.com
www.engineerlive.com 39
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