1. Stave studies 6/15/2013 François-Xavier Nuiry Wolfgang Klempt Fernando Duarte Ramos Miguel Angel Villarejo 1

2. Overview Composite Design Stave prototypes 2 http://www.compositedesign.ch/introduction.FR.html

3. Stave studies 3 Reception of 3 new staves from Composite Design:  Stave 1 layup: -T800 skin, 3 plies [0°, 90°, 0°] (~0.095mm thick) -Rohacell core 51kg/m 3 (Machined) -T800 skin, 3 plies [0°, 90°, 0°] (~0.095mm thick) Thickness: ~1.77mmLength: ~280.2mmWidth: ~25.85mmMass: 3.173g  Stave 2 layup: -T800 skin, 3 plies [0°, 90°, 0°] (~0.095mm thick) -Nida Nomex C2 3.2 29, density 29kg/m 3 -T800 skin, 3 plies [0°, 90°, 0°] (~0.095mm thick) Thickness: ~1.68mmLength: ~280.2mmWidth: ~ 25.9mmMass: 3.448g  Stave 3 (same as stave 2): Thickness: ~ 1.71mmLength: ~280.2mmWidth: ~26mmMass: 3.505g

4. Stave studies Next steps 4 Composite design staves Material properties Glue: DP490 (3M) 150g/m 2  2.18g / stave! Should be 3.5-0.32-2.61= 0.57g Rohacell core 51kg/m 3 Masse in one stave~ 0.56g E=70 MPa Nida Nomex C2 3.2 29, density 29kg/m 3 Masse in one stave: ~ 0.32g MP,EX,2,0.0001 mp,ey,2,0.0001 mp,ez,2,48.26 mp,gxy,2,0.00001 mp,gyz,2,11 mp,gxz,2,15 mp,prxy,2,0.5 mp,pryz,2,0 mp,prxz,2,0 mp,dens,2,0.029E-6 T800 skin, 3 plies [0°, 90°, 0°] (~0.095mm thick) Deduced mass for 2 skins ~ 3.173-0.56=2.61g mp,ex,1,161000 mp,ey,1,8600 mp,ez,1,8600 mp,gxy,1,4870 mp,gyz,1,4870 mp,gxz,1,4870 mp,prxy,1,0.286 mp,pryz,1,0.3 mp,prxz,1,0.286 !mp,alpx,1,-7.65E-007 !mp,alpy,1,15E-006 !mp,alpz,1,15E-006 mp,dens,1,1.570E-6 Source: ESACOMP Coming from ESACOMP Coming from Composite design Coming from rohacell datasheet Loading case for transverse shear modulus calculation: Gxy Gyz

5. Stave Measure and calculation of the bending stiffness 5 Test performed: 3 points bending test Standard used: ASTM D790-02 Configuration: Loading nose and supports radius: 5mm Support span : 180mm and 260mm Loading nose speed: 30, and 62.6mm/min Test stopped when 1.5N are reached Test to be cross-checked with the EN-MME Lab (Mr. Kurt Artoos).

6. Composite Design Staves: Full sandwich Measure of the flexural stiffness 6 FEM simulations: (Total thickness = 1.85mm) 3 points bending test Bow due to both longitudinal elastic modulus (Equivalent) and transversal shear modulus (Rohacell) For a 160mm span Stiffness=8.7N/mm Analytical calculation Flexural stiffness N/mm 2,120,7812,170,7762,240,790 Bending stiffness (EI) N.mm^2 2.79E+052.98E+05 Composite design staves 123 Full sandwich T800 (TPT) Rohacell Nida nomex 180260180260180260 Span (mm)

7. 7 Composite Design Staves: Full sandwich Calculation of the flexural stiffness Composite design staves 123 GeometryFull sandwich Skin MatT800 (TPT) Core MatRohacell Nida nomex BC UX=0 on one supportyes Lesize0,6 Stave width (mm)25,85 25,9 26 Skin thickness (mm)0,09 Core thickness (mm)1,59 1,5 1,53 Span (mm)180260180260180260 Displacement (mm)0,6 Core E modulus Mpa70 48,26 Core G modulus Mpa26,92 Reaction force in the center (N)1,6190,56661,35450,489971,4070,509 Flexural stiffness (N/mm) 2,700,942,260,822,350,85 Bending stiffness (EI) N.mm^23,64E+05

8. 8 Composite Design Staves: Full sandwich Calculation of the flexural stiffness

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10. 10 Staves Comparison of the measured flexural stiffness StaveSkinCoreSpan (mm) Flexural stiffness (N/mm) Masse, g (280mm long stave) Bending stiffness N.mm 2 Natural frequency estimate (Hz) (280mm long stave clamped on both sides) PH/DT cross bracing prototype Stave 8 M55JRohacell 180 mm 1.78 N/mm1.48 g2.39 * 10 5 138 Hz PH/DT sandwich prototype M55JRohacell 180 mm 6.95 N/mm3.74 g16.3 * 10 5 314 Hz CD Stave 1T800Rohacell 180 mm 2.12 N/mm3.173 g2.79 * 10 5 134 Hz CD Stave 2T800 Nida Nomex 180 mm 2.17 N/mm3.448 gtbd CD Stave 3T800 Nida Nomex 180 mm 2.24 N/mm3.505 gtbd

11. 11 Staves Nida modelisation

12. Short – Mid term strategy Discussions 12 Staves: next steps:  Going on calculation / measurement comparisons: -Stave flexural and torsional measurements with Mr. Kurt Artoos? -Study of new designs (filament winding, C-Si foams…) -Order of different prepregs