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Les procédés composites grandes cadences

A quel prix ?

Guillaume CHAMBON ([email protected])

Techno Campus Composites - 09 / 02 / 2017

mailto:[email protected]?subject=Contact suite à présentation JEC CETIM du 09/02/2017

Agenda

2

1 Faurecia Composite Technologies

2 Benchmark

3 Acting the Composite value chain

4 Conclusion

3


2 Benchmark


4 Conclusion

4

Faurecia Clean MobilityComposite Technologies, a division of Faurecia’s strategy in Clean Mobility

Innovations

Passenger cars emission controlCV

on-Highway

Exhaust Energy Recovery Innovations

LightweightInnovations

Exhaust Energy Recovery Innovations

LightweightInnovations

CV

off-HighwayHigh Horse Ppwer

Lightweight composite solutionsEnergy Recovery

for Electrical Vehicle

Real Time Data Fuel Cell Technology

CV Off-highway and HHP Adjacent clean solutions for EV

Air Quality Innovations: Heated Catalyst, ASDS, Turbo Gas, EGR

Current business – Traditional portfolio

Building blocks towards Cleaner Solutions

#1 worldwide in mechanisms & seats structure

#3 worldwide in complete seats

#1 worldwide interior vehicle

#1 worldwide in emissions control technologies

A global leader in its 3 activities

Drive the transformation of the global Mobility Value Chain towards Cleaner Solutions

Procédés composites grandes cadences

Technocampus Composites – 2017-02-09

Faurecia Composite TechnologiesA transversal center of expertise for Faurecia Group activities

5

InteriorsSeating Clean Mobility

o Heat Shields

o Temp. resistance

o Acoustic / NVH

o Functional integration

o H2 tanks

o Seat Structures

o Luggage crash

o Aspect (B-side)

o Acoustic / NVH

o Functional

integration

o A-class body

o Closures

o Rear/side crash

test

o Functional

integration

o Semi-structural & Structural

o Crash resistance &

absorption

o Stiffness & Rigidity

o Underbody / Aero & Skid

Shields

o Acoustic / NVH

o Impact resistance

o Cross-car Beam

o Crash

EV

o Battery Protection

o Crash absorption

o Heat resistance

o Fnct. integration

o A-class

o Semi- & Structural

o Painting

o Functional

integration

Body

Customers



6


2 Benchmark

3 Acting on the Composite value chain

4 Conclusion

BMW case study

7

2013 2014 2016

BIW combining steel / aluminum / CFRP

16 CFRP parts

BMW i3 BMW i8 BMW 7-series

Towards an architecture including composites ‘just-where-needed’

instead of a complete BIW in composite

Oct 2016: BMW announces

they will limit the use of CF,

turning instead to lightweight

steel to keep profit.

CF Life Module (BIW / Life Module)

Aluminium Drive Module

Life Module

Drive Module



Metal : Magna Example

Ultralight door architecture with 42.5% weight savings

Extensive use of aluminum

“Contributions in the area of molding techniques and polymers represented

approximately 7% of the total mass reduction”

“The target in terms of cost was approximately $5 per pound and we came in at

$2.59 per pound”

Status on compositesBenchmark

Composite application in mass market is not established

8

Ultralight Door Module - Magna



9


2 Benchmark


4 Conclusion

Status on compositesThe composite value chain

Mandatory to act on multiple levers of the composite value chain

10

Expectation

Lever - Reduce raw

material price

- Reduce semi-

finished products

- Material compliance

with quick

processes

- Tailored mechanical

performance

- Speed

- Reduce waste

- Reduce scrap

- Reduce post molding

activities

- Automation

- Tailored design

- Function integration

- Hybrid assembly

- Speed

- Reliability

- Reduced trial

number

- Increase material

knowledge &

accuracy

- Engineering &

Development time

reduction

- Global costing

approach

Raw material

Process Product Assembly Engineering

€ € € € €



11


2 Benchmark


4 Conclusion

Raw material


Current trend is to reduce carbon cost to ~ 13€/kg

Next steps :

Working on the carbon fiber value chain to reduce useless steps

2020: OakRidge US National lab: 11€/kg

2023: FORCE : 8€/kg

MaterialCarbon price reduction

12

Carbon fiber cost divided by 2 over a duration of 8 years



Reduce semi-finished products usage

Cost

Geometry freedom

Fenefit from specific material property

Thermoplastic RTM Example

In mold combination of dry fabrics and resin

Integration of ribs

Very high fluidity of caprolactam grants a better fiber impregnation

Opportunity to increase fiber content ratio

Net-shape part production

MaterialMove up the material value added chain

13Procédés composites grandes cadences


Fast Cure application on current production case

MaterialWorking on material to reduce cycle time

14

Potential to reduce even more but bottleneck : Surrounding operations of the closed mold phase

Closed press 21’10’’Open press

2’00’’

Preform

introduction

2’00’’

Mold

closing

0’35’’Closed mold 20’00’’

Mold

opening

0’35’’

Deburring

1’30’’

Weighing

0’30’’

Next

preform

preparation

3’30’’

Operator is waiting 15’00’’

Open press 6’00’’

Demolding

3’30’’Shaper

0’30’’

Mold cleaning

2’00’’

Initial cycle time 29’10’’

Closed press 6’40’’Open press

2’00’’

Preform

introduction

2’00’’

Deburring

1’30’’

Weighing

0’30’’

Next

preform

preparation

3’30’’

Fast cure cycle time 14’40

Mold

closing

0’35’’

Mold

opening

0’35’’

Demolding

3’30’’Shaper

0’30’’

Mold cleaning

2’00’’

Closed mold

5’30’’

Open press 6’00’’

Operator is waiting 0’40’’

Time cycle / 2



15


2 Benchmark


4 Conclusion

Raw material


Fast Form

2 min cycle time

High dimension preforms (up to 3m²)

Stamping

Automatic fibre placement

ProcessFast preform & Automation

16

Fully automated process compliant with automotive mass market

Automation example in plants : 2 SMC parts every 90sec



17


2 Benchmark

3 Acting on the Composite value chain

4 Conclusion

Raw material


Function integration

Benefit of shape freedom

Speak at higher level in the development V-cycle

Move from black metal approach

Benefit of tailored design opportunities

Put the right material at the right place

Playing on

Stacking sequence

Glass / carbon mix

Reinforcement volume ratio

Overmolding

ProductReduce cost and weight

18

Benefit of highly adaptability of composites

Global spec.

Architecture.

Detailed spec.

Detailed design

Unitary test

Integration

test

Validation test

Time

Deta

ils

Function

integration



19


2 Benchmark


4 Conclusion

Raw material


Hybrid assembly

Magnetic Pulse Spot welding

Benefits

Metal insert ok for manufacturing (easier than )

Compatible with multi-material welding with BIW : steel, steel+zinc, aluminum…

Few modification at OEM assembly line

Assembly

20

Quick assembly solution compatible with hybrid materials

Coil

Flyer Sheet

with HumpComposite Plate with

Metallic Insert inside

Air gap Welding

Metallic Insert Steel

Steel + Zinc: e≈0,49µm

Zinc: e≈3,8 µm

Alu + Zinc: e≈3,5 µm

Alu

Welding analysis : perfect adhesion



Composite Assembly

Assembly

21

US welding solution chosen for TP Composite assembly



22


2 Benchmark


4 Conclusion

Raw material


EngineeringEnhanced Engineering scheme

23

If n

ot

OK

Important evaluation

times

No process – product

coupling



Negligible computation time increase by process and costing consideration

Mechanical simulation and costing predictions enhanced with Process Estimator outcome

EngineeringExample of part optimization

7 zones with independent material lay-up

UD and chopped fiber material (carbon & glass)

Zones defined using topology optimizations with an isotropic material

Main process parameter is the injection time (fixed curing time)

Optimization results:

24

Important part cost reduction with process consideration

Standard approach Enhanced approach

Part mass: + 5 %

Part filling time: - 96 %

Total cycle time: - 29 %

Total part cost: - 10 %

1

0

0

&

100 %

1

0

0

&

100 %



25

SB63G1-T1.5 HSR 45-degree angle

0

50

100

150

200

250

0 5 10 15 20 25

Strain (%)

Str

ess

(M

pa

)

HSR Tensile 45° 23C - 0.1 s-1

HSR Tensile 45° 23C - 2 s-1




Optimization

Crash / Energy absorption :

Manufacturing

PROCESS

Raw Materials

And

Sub-Process

PRODUCT

Design Assemblies

Pre-forming / wrapping

Thermoforming

Composite / Composite or

Composite / Metal

Material Laws

SIMULATION applied to COMPOSITES

Engineering

Optimization Optimization



26


2 Benchmark


4 Conclusion

27

EngineeringProduct & Process link

Thermoforming simulation

Process simulation results,

Input for product simulation

Trial

Trial

Product simulation without process consideration

Product simulation with process consideration

Mandatory to consider product-process dependency for complex parts



Composite deployment in Automotive mass market is not established.

Important cost reduction and development of efficient engineering tools mandatory

Mandatory to act on multiple levers in the composite value chain.

Conclusion

28Procédés composites grandes cadences


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