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TRANSCRIPT
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 1 #103130 · 13su0025.pptx
Novel Fibre Reinforced Polymers for the Automobile Interior
Lightweight Structural Components in a Multi-Material Design
HANNOVER MESSE
Materials Forum
Hannover, 10th April 2013
R. Matheis, T. Schulte, L. Eckstein
Institut für Kraftfahrzeuge - RWTH Aachen University
A. Köver
Johnson Controls Automotive Seating
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 2 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 3 #103130 · 13su0025.pptx
Motivation
CFRP in Automotive Applications
Diminishing reserve of fossil fuels
Increasing legislative environmental
constraints
Electric vehicle: Optimising range
(compensate weight of battery)
Reduce mileage independent of
powertrain by lightweight design
Current Situation
Steels CFRP
Need for Research
CO2-Emission Legislation in the EU
Pot. Weight red.: Limited Highest
Maturity Level: High Low
Material Cost: Low Very high
Reduction of material and manufacturing cost of CFRP components
Lower cycle time for potential series production
Integration of steel inlays into fibre components for structure connection
Development of a component showing feasibility of the material concept
CO
2 e
mis
sio
ns
[g/k
m]
40
80
120
160
200
240
2000 20202015201020051995
140 g/km
(2008)
185 g/km
(1995)177 g/km
(2000)
95 g/km
(2020)
0
130 g/km
(2015)
Actual CO2 fleet emissions in the EU
European Union legislative emission regulations
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 4 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 5 #103130 · 13su0025.pptx
The CAMISMA Project
Project Overview
CAMISMA – carbon fibre amid metallic structural interior
component using a multi material approach
Funded by the German Federal Ministry of Education and
Research (BMBF)
Project duration: 01.04.2011 to 31.03.2014
Development of innovative and competitive fibre compo-
sites for vehicle lightweight structures
Reduction of CO2-emissions during the production of
CFRP by using fibre manufacturing by-products
Cost-competitive manufacturing of fibre composite
components (low cycle times and production cost)
Boundary Conditions
Targets
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 6 #103130 · 13su0025.pptx
The CAMISMA Project
Work Packages
Recycling and pro-
cessing of carbon
fibre side products
Design of a multi
material structure
Manufacturing and
functional
improvement
Economic and
environmental
analysis
Production of
preforms
Production of
laminated tapes
Continuous tape
production
In-situ polymerisa-
tion
Identification of ma-
terial properties
Development of a
backrest structure
FEM analysis
Combination of in-
jection moulding and
thermoforming
Validation of process
on demonstrators
Cost analysis of the
lightweight concept
Life cycle assess-
ment
Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco²
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 7 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 8 #103130 · 13su0025.pptx
Development and Production of
Novel Fibre Tapes
Carbon fibre cuttings of different
lengths are
homogenised by cutting
compacted to mats of non woven
fabrics by aerodynamic formation
Filament spreading of unidirectional
(UD) rovings
Continuous impregnation of pre-
forms (UD fibres and non woven
fabrics)
In-situ polymerisation with
thermoplastic Polyamide 12 matrix
Increased adhesion of matrix to
fibres
Low cycle time
Enhanced economic viability
Production of pre-forms Production of laminated tapes
Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco²
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 9 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 10 #103130 · 13su0025.pptx
Targets:
Development of an automobile seat
backrest structure
Combination of non woven and UD CFRP
tapes with injection moulded GFRP,
directly integrating a steel inlay
Weight reduction of 40 %
compared to a reference
Feasibility and economic via-
bility of production progress
Fulfilling passive safety require-
ments (front/rear impact)
Design of a Multi Material Structure
Development Progress
Static
Analysis
Dynamic
Load Cases
Production
Process
+45 -45 Element Density Dicke [mm]
Targets Extensive Use of FEM
Identification of material para-
meters and validation of appro-
priate material models
0
0
Simulation of rear and front im-
pact (static/dynamic)
Optimisation of GFRP topology
and tape layers
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 11 #103130 · 13su0025.pptx
GFRP Injection Mould
Multi-Material Demonstrator
Design of a Multi Material Structure
Multi Material Design
Image Sources: Science-to-Business Center Eco², ITA RWTH Aachen University, HBW-Gubesch Thermoforming GmbH
Reinforcement Rips
Non Woven Fabric Tapes
Back Panel
UD Fabric Tapes
Local Reinforcement
Steel
Recliner Connection
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 12 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 13 #103130 · 13su0025.pptx
Manufacturing of a Demonstrator
Component
Manufacturing Process Proof of Feasibility
Organic
Sheet
Heating
heated
Organic Sheet
SpriForm Tool Forming Process
Injection MouldingMaterial
For Function Integration
Standard Injection
Moulding Machine
Image Source: HBW-Gubesch Thermoforming GmbH
Spri-Form Process
Injection moulding and
thermoforming as one
process step
Steel inlay integrated by
overmoulding
Proof of concept by producing a
sample component
Manufacturing a cut-out of
the final demonstrator
(Currently in preparation)
Manufacturing of the full
back rest demonstrator
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 14 #103130 · 13su0025.pptx
Agenda
Motivation
The CAMISMA Project
Development and Production of Novel Fibre Tapes
Design of a Multi-Material Structure
Manufacturing of a Demonstrator Component
Summary and Outlook
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 15 #103130 · 13su0025.pptx
Summary and Outlook
Filament spreading of unidirectional (UD) rovings
Production of non woven fabric tapes using fibre cuttings
In-situ polymerisation with thermo-plastic Polyamide 12 matrix
Material tests depicted feasibility and good structural properties of novel composites
Successfully integrated novel fibre products in virtual development process
Virtual design of an automobile backrest
Fulfilling safety requirements
Weight reduction of 40 %
Economic manufacturing
Proof of feasibility of spri-form process
Summary Outlook
Implementation of continuous im-pregnation machine
Production of backrest cut-out
Production of full demonstrator
Validation of the requirements
Special focus on crash tests
Cost analysis
Life cycle assessment
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 16 #103130 · 13su0025.pptx
Thank you for your attention!
© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 17 #103130 · 13su0025.pptx
Forschungsgesellschaft
Kraftfahrwesen mbH Aachen
Steinbachstraße 7
52074 Aachen
Germany
Internet www.fka.de
Contact
Johnson Controls Automotive Seating
Industriestraße 20-30
51399 Burscheid
Germany
Internet www.jci.com
Dipl.-Ing. Ralf Matheis Dipl.-Ing. Axel Köver