2017 - atlanta/gacc south · + mapro + axcep 2016 2016 72. carbures mobility index 01 02 03 ......

CARBURESMobility INDEX

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Carbures Group Introduction

Mobility Main Figures

Differential Aspects

Automotive

Quality Management System

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INTRO01

CIVIL WORKS

AUTOMOTIVE MACHINERY

AEROSPACE & DEFENSE MOBILITY

ENGINEERING GmbH

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INTRO01

China

Spain

Poland

USA

Germany

Mexico

18sites

France

CARBon structURESTier 2 Global Company

Technological Advantage

950 Employees

>500 staff in Research, Design and Engineering

2011 2012 20142013 2015

20.0

58.165,2

6.93.3

Carbures Sales (€ Million)

44%

47%

9%

Mobility Aerospace Civil Works

Sales per Sector

1999

University

Spin Off

2006 2012 2013 2015

The Company goes public at MAB

+ MDU+ Composystem

Consolidation & Specialization1st Factory

(Jerez, Spain)

20152014

+ Mapro+ aXcep

2016

2016

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04Carbures Group Introduction



Automotive

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05 Quality Management System

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(x1)

(x3)

FIGURES02

Centers:

• Sales & Engineering Center

• Production

>230

7 countries

2016: 33,1 M

6 manufacturing plants

CARBURES MOBILITY

Mobility figures:

Carbures Mobility US3175 Christy Way, Suite 5Saginaw, MI 48603


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Automotive

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Engineering Partnership

Flawless Project

Management

Strong Leadership

Global Strategy

Technical Background

Collaboration with the Customer since early stages of the

Product development

Own Methodology “SILK” based on Lean Six Sigma

Thinking

High Skilled Management background

Efficiently Balanced Resources and

Worldwide Customers Focus

Expertise from product

development to implement

Equipment's & Manufacturing technologies.

03 DIFFERENTIAL

ASPECTS

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AUTOMOTIVE

MACHINERY

ENGINEERING SERVICES

AUTOMOTIVE MACHINERY

03 DIFFERENTIAL

ASPECTS

RAILWAY


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Automotive

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04Carbon Fiber Friendly Parts (Automotive)

Automotive

RTM: Resin Transfer MoldingSMC: Sheet Molding CompoundPCM: Prepreg Compression Molding

Source: roadandtrack.com

Floor Panels• PCM• RTM• SMC

A, B, C, D Pillars & Reinf.• PCM• RTM

Cowl Panel Firewall• RTM• SMC

Upper Frame• RTM• SMC

Rear Frame• RTM• SMC

Shock Absorbers• SMC• TMP

Side Frame• Braiding - RTM

Hood Frame• RTM• SMC

Roof Cross members• Braiding - RTM• SMC

Tailgate Frame• RTM• SMC

Door Reinforcements• RTM• PCM

Roof Rails & Reinforcements• Braiding – RTM

Lower Frame• Braiding – RTM

Crash box• Braiding - RTM

Tailgate• SMC

Doors• SMC• RTM

Wheel Rim• RTM

Rear Bumper• SMC

Front Bumper• SMC

Roof• RTM• SMC

Hood• SMC• RTM

Side Spoilers• RTM

Front Fender• SMC

Back Fender• SMC

Rear Spoiler/Difusor• RTM

Front Spoiler• RTM

Spoiler• Braiding - RTM

Side Mirror• RTM

Head Lamp Housings• RTM

Dashboard Finishing• RTM• SMC

Door Finishing• RTM• SMC

Seat Structure • TMP• RTM

Steering wheel• Braiding – RTM

Central Console• SMC • RTM

Dashboard Structure• RTM• SMC

Springs• GFRP• CFRP

Engine Covers• SMC• RTM

Oil Pan• SMC• RTM

Stabilizer Bars• Braiding - RTM

Drive Shafts• Braiding - RTM

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1. Baseline: Cast aluminum rim.14 - 15 kg

2. Stress analysis and optimization loops

3. Optimized Product Design8 – 9 kg

SPARE TIRE CROSS MEMBER (STCM) HYBRID RIM

Product design space Geometry optimization

ManufacturabilityWeight optimization

Product final design

Automotive04Composite Product Development Examples

KEY ASPECTS:

• Topological optimization

• Mass production

(100,000 parts/year).

• Over 50% weight reduction

KEY ASPECTS:

• 12 Months Development

• 12 Months Industrialization

• Fully-Automated

Manufacturing

• Target Production Rate

30,000 parts/year).

• >30% weight reduction

• Style / Design Freedom with

the aluminum

• Cost effective solution for

performance

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Automotive04Composite Product Development Examples

LIGHT-TRUCK SUBFRAME ESFERA R&D

KEY ASPECTS:

• Weight reduction (30%)

• Technology change from steel to composite

• High reproducibility

• High production rate

• E-Coating Process Resistance

Top sub-assembly:

• Original: 2 Steel Beams• Solution:

o CFRP Unique BEAMo Local Steel Reinforcements

KEY ASPECTS:

• Design for Manufacturing (DFM)

• Design for Assembly (DFA)

• Mass production

(50,000 parts/year)


• Cost effective solution

KEY ASPECTS:

• Mass production

(50,000 parts/year)


Carbon-fiber frame Hybrid frame

Carbures Mobility holds large experience in production of composite components for prototypes/small/medium/long series and industrialization.

Carbures Mobility is expert in the design and manufacturing of tooling for Low Volume Parts’ Production

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Automotive04

Current Available Technologies

• Prepreg/Infusion Hand Lay-Up + Autoclave or Oven

• VARTM – Vacuum Assisted Resin Transfer Infusion

• RTM (Resin Transfer Molding)

MOLD LIQUID PREPARATION

CUTTING TABLE

CNC / MANUALTRIMMING

FREEZER

ST 10 ST 20 ST 30 ST60 ST 80

Storage of prepreg rolls in

a freezer at -18ºC.

Automatic cut of the 2D ply patterns.

The part is demolded

from the tool and cleaned.

The part goes through a strict quality control to guarantee

the performance.

Trimming, sanding and

polishing of the part to the

desired shape

DEMOLDING VERIFICATION

The mold us prepared

with primers, mold sealers and release

liquids.

ST 70

MANUAL HAND LAY-UP

ST 40

Manual lamination

of the different 2D flat patterns

to a 3D geometry

CURING

ST 50

The parts is cured with

temperature and pressure in autoclaves

or ovens.

Low Volume Production Overview (< 3000-5000 units/year)

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Automotive04Low Volume Composite Production (< 3000-5000 units/year)

SHOW CARSR&D PROTOTYPING

Rear Door Prototype Wiring Prototype

Front Bumper Front Bumper

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SMALL SERIES

SHIFTING PADDLES HEADLAMPSRIMSCHASIS

BODYWORK

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Front Fender

MOTORCYCLE PARTSMOTORSPORT PARTS

Le Mans Series

WTCC

ROAD

TRIAL

COMPOSITE MOULDS TRAIN PARTS

Bodywork Keel * Confidential

STRUCTURAL & INTERIOR PARTS

LIGHTWEIGHT SYSTEMS

High Volume Production (>5000 units/year)

Current Available Technologies• HP-RTM (High Pressure – Resin Transfer Molding)

• RMCP – Rapid Multi-Injection Compression

Process

Future Technologies in Development• PCM – Prepreg Compression Molding

• Surface-RTM, overmolding

• Thermoplastic molding

• Carbon-SMC

Automotive04

Total capacity installed 60.000 parts /year

Carbures Mobility has invested in industrial equipment for manufacturing composite component with low cycles times and high reproducibility.

HP-RTM Line RMCP Line (2018)

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LAMINATIONCUTTING

TABLEMANUAL

DEMOLDINGROLL CHARGE

ST 10 ST 20 ST 30 ST50 ST 70

Manual loading of

carbon fiber rolls.

Automatic cut of the

2D ply patterns.

The part is handled automatically into the

press .While the injection takes place, pressure is applied,

until the part is cured.

Unload the finished part

from the mould to an

intermediate table.

PRESS

Automatic creation of

the plies stacking.

ST 60

Automotive04High Volume Production (>5000 units/year)

HP-RTM Line: 1000 Tonne Dieffenbacher pres and Krauss Maffei Injection Equipment

EXTERNALCNC / MANUAL

TRIMMING

The part goes through a

quality control to guarantee

the performance.

Trimming, drilling and

sanding of the part to the

desired shape

EXTERNAL VERIFICATION

ST40

Fully automated process from 2D ply cutting to part demolding. Structural components that don’t require preforming cell from 2D patterns to 3D shape. Structural parts with constant thickness and medium complexity surface. Structural parts where the preform is manufactured externally.

Capacity 30.000 parts /year

HP-RTM Line Specs:

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LAMINATIONCUTTING

TABLEDEMOLDINGUNWINDING

ST 10 ST 20 ST 30 ST50 ST 70

Manual loading of

carbon fiber rolls.

Electrically driven feeder.

Automatic cut of the

2D ply patterns.

The part is handled automatically into

the press .While the injection

takes place, pressure is applied,

until the part is cured.

In-Line CNC Trimming and drilling of the

part.

Unload the finished part

from the mould to an

intermediate table.

PRESS CNC TRIMMING

Automatic creation of

the plies stacking.

ST 60

PREFORM & CUTTING

ST 40

The stacks are

preformed from 2D

stacks to a 3D shape

Automotive04High Volume Production (>5000 units/year)

RMCP Line: Rapid Multi-Injection Compression Process

Capacity 30.000 parts /year

Fully automated process from 2D ply cutting to part verification (additional Preforming, CNC and Verification stations) The Press is equipped with 4 injection points which has the following process benefits:

Lower unit costs (less pressure and less operational time) Better control of the resin flow (injection strategy improvement, specially for multi-cavity))

Complex parts that require a prefoming station and may have variable sections

Quality control of the

part to guarantee the performance.

VERIFICATION

ST 80

RMCP Line Specs:

Cycle times 6-17 min -> complex big partsCycle times 1-6 min -> small parts


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Automotive

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Regulations20th June 2017

Quality Management System @ Burgo de OsmaTS16949: ISO technical specification aimed at the development of a quality management system that provides for continual improvement, emphasizing

defect prevention and the reduction of variation and waste in the automotive industry supply chain. It is based on the ISO 9001 standard.

IRIS: IRIS stands for International Railway Industry Standard. It is a globally recognized standard unique to the railway sector for the evaluation of management

systems

ISO 14001: ISO Standard on Environmental management system.

OHSAS 18001: ISO Standard on Occupational Health and Safety

ISO 9001: ISO Standard for the Industry

Customer Homologation and TestingAutomotive/Railway OEMs and Tier 1s quality departments inspect and approve start of activities at the suppliers’ facilities prior to Start-of-Production.Carbures must put in place all requirements set by each customer.

On the other side, each component has specific quality requirements (structural, aesthetics, functional,…) and might have testing (mechanical, environment,functional…).

Testing is to be done in authorized test centers for the automotive (TÜV, Applus-Idiada, etc.).

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05 QUALITY

MANAGEMENT

SYSTEM

2017

Carbures.- All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole property of Carbures. No intellectual property rightsare granted by the delivery of this document or the disclosure of its content. This document shall not be reproducedor disclosed to third party without the express written consent of Carbures. This document and its content shall notbe used for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. They are based on the mentioned assumptions and areexpressed in good faith. Where the supporting grounds for these statements are not shown, Carbures will bepleased to explain the basis thereof.

In case of questions for commercial usage please get in contact with us.

2017 - atlanta/gacc south · + mapro + axcep 2016 2016 72. carbures mobility index 01 02 03 ......

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