Simulationsbasierte Entwicklung eines Kohlenstoff-Nanopartikel-basierten Heizsystems zur energieeffizienten Herstellung von kohlenstofffaserverstärkten Kunststoffbauteilen mit konturnah beheizten Formwerkzeugen

This work deals with the simulation-based development and implementation of an energy-efficient variant for the production and curing of fiber-reinforced plastics using a novel nanoparticle-based 3D tool tempering system. The current production process of CFRP components in the autoclave was analyzed with temperature measurements and flow simulations and various possibilities are presented to increase the efficiency by a conformal heating of the mold and reducing thermal masses respectively the overall heat capacity. Functional heated tool demonstrators, including electronic control technology, were designed and produced, as well as a process chain for the automated production or conversion of molds is shown. CFRP components were cured as a function test of the tool and the new process options were analyzed. In addition to the experimental heating system development, various process simulations on micro and macro scale were carried out. This work presents methods to support the different process steps from autoclave curing or curing with heated tools (composite curing with the finite element method), the definition of design parameters of the carbon nanotube reinforced heating system (electrical conductivity of nanocomposites) and the automated application onto the tool surface. The energy efficiency has been calculated for various processes (inside and out-of-autoclave) and it is shown that the energy consumption can be drastically reduced by the use of conformal heated tools. Finally, the developed 3D tool tempering system and the automated production were tested for a broader implementation and a profitability analysis was prepared.