Page 53 - Research Report 2021 - Institut für Leichtbau und Kunststofftechnik

PEP4.0

Development of a highly efficient linked product
development process (PEP) for hybrid lightweight
structures in the context of industry 4.0

In the project PEP4.0, the ILK is collaborating with Rolls-Royce Germany to Period
research efficient methods for the development of an intermediate engine 01.07.2018 – 30.06.2023
casing (IMC) in metal-fibre reinforced composite design (cf. Fig. 01). The basis
for this is a digitally linked product development process that combines the Project management
methods, models and data of the individual disciplines of design, dimension- Prof. Dr.-Ing. habil. Maik Gude
ing and manufacturing into a linked development structure from the specifi-
cation of requirements through to production (cf. Fig. 02). Contact
Dr.-Ing. Sebastian Spitzer
Using this interlinked approach, it was possible to successfully develop a hy-
brid design of the IMC in which structural loads are transferred from the inside Project partners
of the engine to the outside via aerodynamic guide vanes made of fibre-plas- Rolls-Royce Deutschland Ltd. & Co. KG
tic composite. There, a fibre composite ring with a diameter of about 1.20 m
takes the loads, merges them at one point, where they are then transferred Funding
to the aircraft fuselage. Via this load path, the thrust generated inside the en-
gine can be used to propulsion the aircraft.

The guide vanes consist of variable-axis arranged fibres that are suitable for
the load path and are positioned using the Tailored Fiber Placement method.
The engineering design process set up to realise such a structure is a world
first and could only be achieved through digital linking and the close cooper- Federal Ministry for Economic Affairs
ation of the project partners with Leibniz-Institut für Polymerforschung Dres- and Climate Action (BMWK): Federal
den (IPF) and Hightex Verstärkungsstrukturen GmbH. Aviation Research Programme LuFo V-2
Funding code: 20X1717B

Managed by:

German Aerospace Center (DLR)

Fig. 01 Rolls-Royce Pearl 15 (left), metallic aerodynamic IMC of the Pearl 700 (centre) and
fibre reinforced composite metal IMC of future generations (right).

Fig. 02 Interaction of the individual disciplines of component design, dimensioning and
manufacturing within the development of CFRP structures.

53