+ 2019 FORMICA – Incremental forming of thermoplastic composite materials

Project promoter

Nahiene HAMILA Associate Professor - INSA Lyon

nahiene.hamila@nullinsa-lyon.fr

Member laboratorie(s)


DURATION : 3 yeras

FUNDING : 202 800 €

INDUSTRIAL SECTOR :  aeronautics, automotive, chemicals and materials, naval and maritime industries

PLATFORMS INGENIERIE@LYON : Materials and processes, Robust design, Energy/Environment

 

Area(s) of search

OBJECTIVE

The reduction of polluting emissions and the lightening of vehicles require the use of new materials or assemblies previously reserved for niche applications. Thermoplastic matrix composites have been of great interest in recent years because they meet this need for mass reduction while guaranteeing high mechanical strength. One key challenge is the cost reduction of the manufacturing and processing of these materials. On the one hand, current manufacturing methods do not allow complex shapes to be obtained easily. On the other hand, in order to be competitive, the final product must integrate additional functionalities: stiffeners for mechanical strength or electronics for so-called "smart" functions.
 
The FORMICA project proposes to study a new method of composite manufacturing called "incremental forming" using the prism of shaping modelling to facilitate the deployment of this technology. The purpose of incremental forming is to gradually form the composite blank by controlled movements of the moulding cavity. This type of process should reduce final defects on the part in service, improve formality and facilitate the integration of printed sheet electronics. This will make it possible, through close collaboration between the two laboratories LaMCoS and Cethil, with the IPC Technical and Industrial Centre, to control the link between the production of the material and its behaviour under service. The IPC will provide an incremental forming tool in which the integration of electronics will be tested. LAMCOS and CETHIL will collaborate on the modelling part in order to take into account the thermal history in the constitutive behavior model. Two materials with two different crystallization histories will be different, and introduction by more representative state variables, such as crystallinity, would be appropriate.

Building on the previous work of the laboratories that led to a TRL 1 to 3 level, the project aims to develop the scientific knowledge of the laboratories (TRL 4) and to benefit from the human and experimental resources available at the IPC in order to validate these technologies in a real environment (TRL 5-6).

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