Center of
Composite
Technology
TUPOLEV KAZAN NATIONAL RESEARCH TECHNICAL
UNIVERSITY-KAI
CENTER OF COMPOSITE TECHNOLOGY
RESEARCH AND DEVELOPMENT OF NEW PROCESSES OF
REINFORCEMENT STRUCTURES MANUFACTURING AND
COMPOSITE PARTS USING THESE STRUCTURES
Vladimir Batrakov
Associate Professor, Candidate of Engineering
Head of Process Department, Center of Composite Technology
TUPOLEV KAZAN NATIONAL RESEARCH
TECHNICAL UNIVERSITY-KAI
Center of
Composite
Technology
Tupolev Kazan National Research Technical University was established in 1932. Till 1992 it was known as
Kazan Aviation Institute (KAI). In 1973 it was named after outstanding aircraft designer Andrei Nikolayevich
Tupolev.
Aircraft Manufacturing Department was established in 1934. Since 1999 the Department has been a part of
Aviation, Surface Transport and Power Engineering that was founded the same year.
GRADUATED FROM KAI:
Ivan S. Silaev
5th Minister of
Aircraft Industry,
USSR
Mikhail P.
Simonov
Lead Designer of Sukhoi
Experimental Design
Office
Center of
Composite
Technology
Boris I. Gubanov
Lead Designer of
“Energy” rocket
FUNCTION OF THE CENTER
Center of
Composite
Technology
Research and Development in the area of
Composite Technology
Development of New Technology
Engineering Solutions
Transfer of new processes into batch production
A wide range of materials and prototypes studies
Training (advanced training) of industrial employees
EDUCATION:
Training. Courses are as follows:
•
Aircraft Construction 160100;
•
Material Science and Technology 150100
Major – Composite Parts Design and
Manufacturing
Advanced Training
for employers of universities and industrial
enterprises
Center of
Composite
Technology
Center of
Composite
Technology
EDUCATION
Training. Courses are as follows:
•
Aircraft Construction 160100;
•
Material Science and Technology 150100
Major –
Composite Parts Design
and Manufacturing
Advanced Training
PERIODS OF CENTER DEVELOPMENT
Center of
Composite
Technology
1991 – development of sound absorbing structures
(for Kuznetsov SNTK, Samara)
2001 – working for Airbus, EADS, Diehl Aircabin GmbH
2009 – Program of National Research University Development
2010 – working for Central Aerohydrodynamic Institute,
JSC AeroComposit, etc.
Center of
Composite
Technology
STRUCTURE OF CENTER OF
COMPOSITE TECHNOLOGY
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Material Science
Компьютерного
Design and Simulation
моделирования
Composite
Технологии
КМ
Technology
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Sandwich
Многослойных
Sandwich
Sandwich
конструкций
Structures
Structures
Structures
Испытаний
Testingна
статику и удар
Processing
Подготовки Tooling
технологической
Manufacturing оснастки
Transfer Molding
Трансферного
формования
Innovative Equipment
Инновационного
оборудования
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
Design and Simulation
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Инновационного оборудования
Center of
Composite
Technology
GENERAL IDEA – IMPLEMENTATION OF DIGITAL TECHNOLOGY
Structural Analysis
and Processes
Simulation
Parts and
Tooling Design
Clean Zone
working with composites, cutting,
layup and preforms
manufacturing
Tooling
Manufacturing
INTEGRATED DIGITAL DATABASE
Transfer Molding
Autoclave Molding
Geometry and Quality
Control
Material Properties
Center of
Composite
Technology
SOFTWARE PACKAGES INTRODUCTION
Achieving new level of development and organization of composite
parts production processes through integrated digital environment.
ESI Group Software
Impregnation, shaping and
autoclave molding simulation
FiberSim Software
Cutting, layup maps generation, draping
evaluation and operation management
using digital software
SOFTWARE APPLICATION
Designing composite parts in FiberSIM Software
• Simulation of layerwise reinforcement material layup
• Rendering of the areas with folds and cuts on reinforcement material
• Obtaining initial data for calculation software (ANSYS, PAM-RTM, etc)
• Creation of cutting pattern and layers projection on the tooling
• Design of mating mold surface
Center of
Composite
Technology
PART MANUFACTURING SIMULATION IN ESI GROUP
SOFTWARE
Center of
Composite
Technology
Part impregnation scheme
«spar to tail»
Part impregnation scheme
«sides to center»
Part impregnation scheme
«center to sides»
Macro and micro voids content in
non-optimized scheme
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Material Science
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Инновационного оборудования
Center of
Composite
Technology
MATERIAL SCIENCE LABORATORY
Study of physical and chemical properties
Rheometer HAAKE RS6000
(ThermoScientific)
IR Fourier Spectrometer (Bruker Tensor 27)
Polylite 507-574+Peroxid-2
Eta = f (t)
Polylite 507-574+18Peroxid
Eta = f (t)
5,0
4,5
4,0
3,5
Eta in Pas
3,0
DSC 204 F1 Phoenix (Netzsch)
1
2,5
2
2,0
1,5
1,0
0,5
DMA
0
0
7,4
14,8
22,2
t in min
29,6
37,0
Center of
Composite
Technology
PHYSICAL AND CHEMICAL ANALYSES OF COMPOSITES
№
1.
Type
Rheology of resins and compositions
Equipment/ Method
Standards
Dynamic rotational rheometer
(viscosity of compositions subject to
temperature, shear velocity, rheokinetics of
cure)
2.
Cure kinetics study
Differential scanning
calorimeter (DSC)
ASTM D 3418
(ΔH, cure initiation temperature, maximum
therm temperature)
3.
Glass transition temperature
Dynamic mechanical analyzer
(DMA)
4.
Retention Modulus (E') and Loss
Modulus (E"), tan delta
Dynamic mechanical analyzer ASTM D 4065
(DMA)
5.
Liquid Density
Bottle Method
Solid Density
ГОСТ 15139-69
Hydrostatic Weighing Method ГОСТ 15139-69
6.
ASTM D 1475
ASTM D 792
Electronic Balance
7.
Water Absorption
MATERIAL SCIENCE LABORATORY
Center of
Composite
Technology
Determination of compressibility and permeability
of reinforcement fabric
Flow monitoring system
Determination of compressibility and
permeability of reinforcement fabric
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
моделирования
Composite
Технологии
КМ
Technology
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Инновационного оборудования
PROCESSING LAB
Complex for cutting, layup and preforms manufacturing
Center of
Composite
Technology
Clean Zone (ISO Grade 7 & 8 )
Digital Plotter ZUND
3D Laser Projector LAP
Thermal Vacuum Press
PROCESSING LAB
Clean Zone
«Clean zone».
Range of purity ISO 7, 8
Provides conditions
required for handling
composites
Total area: 70 sqm. Clean zone is
equipped with the following machinery:
Main equipment:
-Laser 3D projector – digital methods of
layup of reinforcement materials.
- Cutter (Zünd, Switzerland) – cutting of
reinforcement materials
Center of
Composite
Technology
PROCESSING LAB
Equipment for TFP preforms manufacturing
Center of
Composite
Technology
PROCESSING LAB
Ultra-violet curing of composite parts
Center of
Composite
Technology
PROCESSING LAB
Center of
Composite
Technology
Radial braiding and tufting machine
Manufacturing preforms by
circular braiding
PROCESSING LAB
Complex for autoclave and press molding
Panini autoclave (Italy)
Hydraulic press
Pneumatic press
Center of
Composite
Technology
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Подготовки
технологической оснастки
Transfer Molding
Трансферного
формования
Инновационного оборудования
Center of
Composite
Technology
TRANSFER MOLDING LAB
RTM Complex
(Press + Wolfangel
RTM machine)
Automated thermal
infusion center (SAT +
Isojet)
TRANSFER MOLDING LAB
Infusion machine Vacmobile
(Italy)
Center of
Composite
Technology
RTM and Light-infusion machine
Wolfangel (Germany)
(polyether resins)
TRANSFER MOLDING LAB
Center of
Composite
Technology
Equipment for material state-based on-line control and optimization
of composite parts molding
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Sandwich
Многослойных
конструкций
Structures
Испытаний на
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Инновационного оборудования
SYNTHESIS OF FOLDED CORES
Designing sandwich structures with light cores;
development and optimization of manufacturing
technology
Center of
Composite
Technology
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Innovative Equipment
Инновационного
оборудования
EQUIPMENT FOR SYNCHRONOUS FOLDING
Center of
Composite
Technology
33
EQUIPMENT FOR CYCLIC FOLDING
Development of sample equipment
Center of
Composite
Technology
Center of
Composite
Technology
CCT LABORATORIES
Материаловедения
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
статику и удар
Processing
Подготовки Tooling
технологической
Manufacturing оснастки
Трансферного формования
Инновационного оборудования
MANUFACTURING AND CONTROL OF PROCESSING TOOLING
Center of
Composite
Technology
CCT LABORATORIES
Center of
Composite
Technology
Материаловедения
Компьютерного
моделирования
Технологии КМ
Центр
CENTER
OF COMPOSITE
Композитных
TECHNOLOGY
Технологий
Многослойных
конструкций
Испытаний на
Testing
статику и удар
Подготовки
технологической оснастки
Трансферного формования
Инновационного оборудования
LABORATORY OF STRENGTH AND IMPACT RESISTANCE TESTING
Universal electric mechanical machine
Instron 5882 (USA) (100 kN)
- Environmental camera
Temperature range от -150°С … +350°С
- Contact extensometers EPSILON
- Tensometric Station
- Tooling ASTM D-3410, D-3039, D 6641, D
7137, D-5379 ISO 1209-2
Center of
Composite
Technology
TYPES OF TESTING
Tensile Testing (ASTM 3039М, GOST 25.601-83):
At normal, high and low temperatures
Ultimate Tensile Strength
σ+, MPa
Tensile Modulus
Е+, MPa
Elongation at Break
ε, %
Poisson Ration
μ12 μ21
Compression Testing (ASTM 3410М, GOST 25.602-80):
At normal, high and low temperatures
Simple Compression Testing (ASTM
6641M) (нестесненное сжатие):
Ultimate Compression Strength
σ -, MPa
Compression Modulus
Е-, MPa
Center of
Composite
Technology
TYPES OF TESTING
THREE POINT BENDING
GOST 25.604-82, ASTM D 790 ISO 1209-2
SHORT BEAM SHEAR
GOST 25.604-82, РД 50-075-88, ASTM D 2344
FOUR POINT BENDING
GOST 25.604-82, ASTM D 6272, ISO 14125
IN-PLANE SHEAR
ASTM D 3518
Center of
Composite
Technology
IMPACT RESISTANCE TESTING
Vertical impact machine
Instron 9200 Dynatype (USA)
Test Methods:
ASTM D-7136, ASTM D-256, ASTM D-6110
Center of
Composite
Technology
POLYMER IMPACT ELASTICITY TESTING
Center of
Composite
Technology
Izod and Charpy
impact tests:
ASTM D-256,
ASTM D-6110,
ISO 179, 180
Pendulum impact machine (мах 25 J)
Instron CEAST (USA)
Instrumented pendulums for
resins and polymers testing up
to 5 kN
NON-DESTRUCTIVE TESTING OF COMPOSITES
Ultrasound crack detector Omniscan MX2
Manual scanner
A set of ultrasound sensors on phaselocked array 64 elements 3,5 and 5 MHz
Center of
Composite
Technology
Center of
Composite
Technology
WORK EXPERIENCE
with domestic and foreign Customers
WORK EXPERIENCE
We are cooperating in the field of research and development
with leading domestic and foreign companies from aircraft
industry
1. AIRBUS SAS (Toulouse, France) since
2001
2. EADS (Munchen, Germany) since 2006
3. Diehl Aircabin GmbH (Germany) 2010
4. VIAM (All-russian Scientific Research
Institute of Aviation Materials) (Moscow,
Russia) 2005, 2007
5. OJSC KAMAZ 2010-2012
6. CJSC AVIASTAR-SP (Ulyanovsk) since
2008
7. CJSC INUMIT (Moscow) since 2009
8. JSC NPP Rubin (Penza) 2010
9. JSC Aviadvigatel (Perm) 2010
10. Central Aerohydrodynamic Institute
(Zhukovskiy) since 2010
11. CJSC AeroComposit (Moscow) since 2011
12. JSC Kazan Helicopters (Kazan) since 2012
13. JSC NPO Saturn (Rybinsk) since 2012
Center of
Composite
Technology
Center of
Composite
Technology
WORKING FOR AIRBUS SAS
«FOLDED CORES» CONTRACT
DEVELOPMENT OF FOLDED CORE MANUFACTURING
TECHNOLOGY
Center of
Composite
Technology
VESCO PROJECT
Center of
Composite
Technology
Development of structure and method of
synchronous manufacturing of Nomex
folded core with single curvature for
fuselage panels.
VESCO Project (Airbus GIE (Germany))
AIRBUS SAS,
SAS, EADS,
EADS,
Diehl Aircabin GmbH
DETERMINATION OF STRENGTH, IMPACT RESISTANCE AND
DURABILITY OF SANDWICH PANELS
Center of
Composite
Technology
Center of
Composite
Technology
FULL-SIZE PANELS TESTING
Full-size testing sample
VeSCo2 (Germany)
Test Facility (IMA Dresden)
Center of
Composite
Technology
WORKING WITH DOMESTIC CUSTOMERS
DEVELOPMENT OF CORES FOR ACOUSTIC PANELS FROM
AIR-PERMEABLE MATERIALS AND THERMOPLASTIC
COMPOSITES
Center of
Composite
Technology
Center of
Composite
Technology
OPTIMIZATION OF AUTOCLAVE MOLDING MODES AND STUDY OF
NEW POLYMER COMPOSITES
Напряжение при растяжении (MPa)
1100
1000
900
800
700
600
500
400
300
200
100
0
0.000
0.002
0.004
0.006
0.008
0.010
0.012
0.014
Осевая деформация (Видео) (mm/mm)
ИНУМИТ ЗАО,
(МГУ, Москва)
DEVELOPMENT OF PROCESSES FOR INTEGRAL
AIRCRAFT PARTS MANUFACTURING
Center of
Composite
Technology
Spoiler - RTM
Passed static and fatigue testing
Spoiler with integral
racks
Customer - AeroComposit
Impregnation scheme
simulation
SPOILERS MANUFACTERED IN CCT
Center of
Composite
Technology
CONCEPTS OF INTEGRAL STRUCTURES
Center of
Composite
Technology
ФГУП ЦАГИ
ОАО «Авиадвигатель»
DEVELOPMENT OF AIRCRAFT PARTS AND POLYMER
TOOLING MANUFACTURING PROCESSES
ANSAT helicopter with
composite tail rotor fairing
manufactured by CCT
MAKS-2013 exhibition
Center of
Composite
Technology
TECHNOLOGY FOR AIRCRAFT ENGINE COMPOSITE PARTS
MANUFACTURING
SATURN R&D production facility (Rybinsk, Russia)
Center of
Composite
Technology
DEVELOPMENT OF PROCESSES FOR LARGE
COMPOSITE PANELS PRODUCTION
Infusion and Light-RTM for large composite automobile parts production
Stages of Light-RTM manufacturing process
Infusion impregnation
Center of
Composite
Technology
DEVELOPMENT OF PROCESSES FOR LARGE
COMPOSITE PANELS PRODUCTION
Assembly of pilot batch of cabs, KAMAZ
Center of
Composite
Technology
DESIGN OF AIRCRAFT HOLDING FRAME
Customer – JSC AVIASTAR-SP
Center of
Composite
Technology
DEVELOPMENT OF NEW SOUND ABSORBING AND SOUND
INSULATING FOLDED CORE FOR AIRCRAFT SANDWICH PANELS
Samples of sound absorbing structures and equipment
for acoustic properties study (Kundt’s pipe)
Center of
Composite
Technology
SIMULATION AND EXPERIMENTAL TESTING OF SANDWICH
STRUCTURES DESTRUCTION MECHANISMS
Simulation in ANSYS\LS-DYNA Software
Center of
Composite
Technology
Center of
Composite
Technology
DEVELOPMENT OF COMPOSITE ANTI-MINE
PROTECTION BASED ON FOLDED ENERGY ABSORBING
PANELS
S1
S2
Area ratio
S1
S2
Multilayer folded
panel
Target: weight reduction of armoured vehicle due to
application of authentic structure and new materials
= 4 ÷10
THANK YOU FOR YOUR ATTENTION!
Center of
Composite
Technology
ADDRESS:
CONTACT:
TUPOLEV KNRTU-KAI
K. Marx St., 10
420111 Kazan
Russia
Head of Aircraft Manufacturing Department
Professor Valentin I Khaliulin,
Doctor of Engineering
www.kai-composite.com
Tel/Fax: (843)-236-64-94, Tel :236-52-42
E-mail: [email protected]