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1
Design and Manufacturing of a
TP Composite Bumper Beam by QSP®
JEC world 2017 conference
CETIM : Damien Guillon, Clément Callens
SNOP : Mickaël Moscardo, Eric Deprun, Georges TEIXEIRA
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A regional, national and international player:
➢ 115 M€ turn over,
➢ 900 employees,
➢ 8 sites in France,
➢ 44,000 m² of laboratories and platforms
➢ 3 subsidiaries in France and North Africa
Part of a strategic French R&D network:
➢ Covering all topics in the mechanical field with 9 open labs with universities
➢ Paving the way to innovative technologies on the whole product’s lifecycle
A strategy geared around innovation:➢ R&T development & support for more than 4,000 customers per year➢ Acting in standardization committees (216 seats)
Cetim the french innovation maker in mechanics
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Cetim Composite at a glance:
Polymer Material expertise for 40 years
+120 PhD, Engineers and Technicians
18M€ turn over in composite activity
Scientific partnership with:
ECNantes,
ENSCachan,
Onera,
Imperial College of London
Industrial partnership with AFPT for Spide TP
and Pinette, Loiretech and Compose for QSP
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Key Figures
➢ 834 M€ turn over,
➢ 5740 employees,
➢ 27 manufacturing plants
➢ Operating in 11 countries
➢ 400 000 Tons of steels stamped per year
3 main activities:
➢ Development and industrialization Manufacturing of BIW subassemblies
➢ Design and manufacturing of stamping dies
➢ Design and manufacturing of production means : presses and roll forming lines
Advanced Engineering :
➢ Reason for being part of the project consortium : Weight reduction thought usage of Composite must be anticipated and Product/Process knowledge acquired early.
SNOP – French leading Supplier for Body in White
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TP composite bumper beam project
Demonstration of the QSP capability
Results of a three years long process development project
A one year long part development
Design :
Specification and validation by SNOP, automotive bumper supplier
Optimization methodology to choose the better lay-up configuration
Process simulation in input of mold design and product simulation
Manufacturing
Use of in house pultruded tape
Continuous automated production with less than 2 minutes cycle time
Testing and costing
Real performance and accurate cost analysis
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Design : Use of optimization methodology
Optimization results : Thickness and anisotropy in each area
5mm thicknesswith 95% of 0° fiber
5.5 mm thicknesswith 50% of 0° fiber
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Design : Process analysis for real composite sizing
Use of « drape estimator » :
Real fiber orientation in
calculation
Choice of ply shape to avoid
material scrap
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Design : Forming Simulation
Use of Hyperform :
Validation of process estimation with explicit Finite Element Analysis using fabrics
material and inter-ply contact behavior
Precise patch shape definition and lay-up position
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Multi-thickness / multi-orientation / multi-material solution
Composite part lay-upTwo versions of patch 1 and 9 : - 4:1 fabrics- UD tape 1,2mm 0° + 0,3mm 90°
Multi-material front end bumper system1,8kg composite + 0,5kg plastics + 1,3 kg aluminium + 0,1kg rivets= 3,7 kg total weight
26% mass saving on the steel reference
①
②
③
④
⑤
⑥
⑦
⑧
⑨
Welding of aluminium part
Riveting of the beamsandwiched betweenaluminium parts
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Specification fulfill!
Test case Target
Damner crash
16 km/h
Fmax < 65 kN OK
Eabs > 4000 J OK
No Body in white damage OK
Front Pole test crash
25km/h
Finit > 20 kN OK
No final failure before 200mm calculation OK, test TBC
RCAR Bumper crash
10,5km/h
Fmax < 65 kN calculation OK, test TBC
Eabs = 3100 J calculation OK, test TBC
Enfoncement maxi. = 70 mm calculation OK, test TBC
ECE42 parking crash
4km/h
Flèche < 30mm OK
No damage OK
Towage
750daN (30°/40°)
No damage OK
Sufficient Stiffness OK
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11 General possibilities of the QSP® (Cetim’s pilot line)THERMOFORMING &
OVERMOULDINGTo add a maximum value
intra-mold& get a netshape part
RAW MATERIALS
Fibers & Thermoplastic
HIGH SPEED CUTTINGTo cut all patches needed for the multi-thickness preform
TP PULTRUSIONTo create semi-products with a low cost and high
speed of production FAST HEATINGCombining conduction & High-Speed IR ovens for multi-thickness preforms
PREFORM ASSEMBLYTo make an automated assembly of a multilayer “netshape” preform < 1min
HIGH SPEED TRANSFER< 5sec
Any other organosheets or tapes
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12 From the raw material to the preform
Pultrusion of the main reinforcement
85% of the part’s mass at lower cost
The right width to avoid scrap
The optimized thickness (1,2 mm)
and 50% volume of fibre content.
0% of scrap thanks to
rectangular cut patern
Patch 1 Patch 9 Patch 62 34 5
78
Cut patern of the pultruded tape (230 mm specific width)
Cut patern of the thin CELSTRAN tape (305 mm standard width)
1a 1b 1c1d9d
9a 9b 9c
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13 From the preform to the part
95 seconds heating time (5,7mm maximum thickness)
Temperature homogeneity (deviation<20°C) thanks to combined ovens
Forming, holes drilling and
overmoulding in one step
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15 Testing
« Parking » low velocity
ECE 42 crash test
No damage
-40
-30
-20
-10
0
-40 -20 0
Forc
e (
kN)
displacement (mm)
Test simulation
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16 Testing
Pole test 36km/h
No final breaking
before 200mm of
intrusion, thanks to a
progressive failure
0
2
4
6
8
10
0 50 100 150 200
Forc
e (
kN)
displacement (mm)
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17 Economical summary
Detailed cost analysis according to automotive standard have been made
Function integration needed to enhance the performance/cost ratio.
Step Price
Composite material (prepreg price 3€/kg) 5,7 €
Cutting 0,6 €
Plastic material (compound price 3€/kg) 1,2 €
QSP 3,4 €
Composite beam total 10,9 €
Aluminium parts 11,2 €
Final assembly 1,8 €
Total system cost 23,9€
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19 Key Benefits of QSP Bumper beam
Multi-thickness/multi-orientation preform
- 20% of composite mass compared to a constant thickness design
Proven and efficient industrial process
300,000 part/year capacity demonstrated on CETIM pilot line
With 2 cavities on a 500T press
Acceptable over-cost (comparable with the one for aluminium solution)
Prepreg price of 3€/kg possible with a 3 meters/minute pultrusion process
Freedom in material choice and 0% scrap design
Ability to mix pultrusion, fabric sheet, thin tape, and to integrate local carbon patches
Come and visit us : Composites in action - Hall 5a - Stand M81
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