TIE RODS MADE OF HIGH-PERFORMANCE COMPOSITE FIBERS
With the Austrian company Teufelberger Composite GmbH, HIRSCHMANN has the ideal partner at its side to realize their innovative products for aerospace. They have decades of experience in development and manufacturing of fiber ropes. For the HIRSCHMANN innovation, Teufelberger produces the Tie Rods (coupling bars) as connecting elements between the LW spherical bearings. These extremely resistant stabilizers are a mesh of high-tensile, high performance composite fibers such as carbon, glass, or aramid. For processing the preform, Teufelberger prefers the Composite braiding technology resulting in a defined braiding of hollow bodies.
The braiding process for composite fibers is done by radial plaiting machines. In these machines, the composite fibers are departed in controlled angles and in several layers with the help of specially designed bobbins on a braiding core, and are moved through the machine by a robot. Additional fibers in longitudinal unit direction (UD filaments) are placed over the machine circumference along the axis of the braiding core. The forming hose covers the shape of the braiding core exactly, and a preform is made that already corresponds to the final contour of the component being manufactured. The braiding technology is predestined for automated manufacturing of multilayer, three-axial hollow meshes made of composite fiber materials and allows the production of various component geometries near to final contour. For optimum strength, a resin is injected into the mesh in RTM process (Resin Transfer Molding).
Braider with robot
Hybrid meshes – different types of fibers within one mesh layer – are a special feature of Composite braiding. Because the mesh is closed completely only on the component surface, it is possible to add additional elements as the patented T-IGEL® connecting technology.
Into the joint elements with T-IGEL® connection, made by 3D-printing in titanium, the aluminum-titanium spherical bearings are pressed and rolled in by HIRSCHMANN at a later stage. Further on in production process of the Tie Rods, the core braided with composite fiber materials is solved and washed out in a water quench. The result of this process is ultralight, hollow inside, but extremely resilient Tie Rods.
The stabilizer bars are available in different lengths and diameters. A special program calculates according to the application, where the highest forces should be transmitted – this point is basis for material thickness. Available are units with a diameter from 25 to 300 mm in length up to 15 m. Depending on component diameter, machine size, and type of composite fiber braiding angle in the range of [-25/25°] up to [-85/85°] can be realized.