Curved Composites

Compared with conventional structural profiles, profiles made of fiber-reinforced plastic (FRP) are characterized by both high lightweight potential and excellent resistance to corrosion. Up to now, FRP-profiles have mainly been manufactured from thermoset matrix materials. Since they crosslink irreversibly, profiles produced in this way can no longer be deformed. Therefore, if curved profiles are to be manufactured, a separate tool is required for each individual radius of curvature. Together with the Chair of Forming Technology at Siegen University (UTS), Gustav Gerster GmbH & Co. KG and Bilsing Automation GmbH, IVW is researching material and process technologies that aim at enabling the variable bending of initially straight FRP-profiles. A major innovation is the impregnation of the textile reinforcement with reactive thermoplastics. While retaining the favorable thermoset processing route, these exhibit subsequent hot-forming capability of the matrix. This would allow straight profiles to be produced as standard and subsequently bent to the desired radius. Current research work, besides the development of a bending unit by Bilsing and UTS, is concerned with the design of the textile reinforcements (IVW and Gerster). The textile reinforcement is absolutely critical for the bending process and defines the process limits. The textile architecture should - while retaining the mechanical properties as far as possible - give the manufactured profile the greatest possible forming capability, but at the same time must neither tear nor wrinkle during forming.

The aim of the Curved Composites project is to produce subsequently formable FRP-profiles based on the impregnation of drapeable reinforcement textiles with a thermoplastic resin system.

Partners:

• Bilsing Automation GmbH
• Gustav Gerster GmbH & Co. KG
• Lehrstuhl für Umformtechnik der Universität Siegen (UTS)