Materials Forum Intelligent-Lightweight Constructionfiles.messe.de/abstracts/57934_Wesolowski.pdfMaterials Forum, HMI 2014 / page 16 AIDA, TUNNEL-ELEMENTS curved ceiling elements in

Materials Forum, HMI 2014 / page 1

Materials Forum Intelligent-Lightweight Construction

Design examples for lightweight structures with aluminium sandwich technology

Dr.-Ing. Klemens Wesolowski

1


Sandwich Constructions

Physical behaviour

CORE MATERIALS + ALUMINIUM COVER SHEETS

- Stiffness - Thermal insulation - Good thermal conductivity - Acoustic - Pressure resistance - Fire resistance - Energy absorption

Cork

PET foam

Alumiunium Corrugation

Alumiunium Cells


Production of Sandwich Materials

2 Component–adhesive on bottom sheet

- Top sheet - Next sandwich in batch process - Pressing (e.g. with steel plates)

TAILOR MADE PRODUCTION

- Core layer (e.g. cork) - Adhesive layer


continuous production process (including core material from coils)

pre-treatment already on the coil corrosion-protection also on the core material use of hotmelt adhesives (polyamide basis)

Metawell® production

4

Production of Sandwich Materials

CONTINUOUS PRODUCTION LINE

Processing scheme


CROSS SECTION of a Metawell® panel

The core material of Metawell® is made of a thin metal corrugation, which is inserted between the cover sheets continuously and without joints.

The corrugated core material has got a hight inherent stiffness through the geometry, adopted from nature.

DESIGN

5

Metawell® – the product


Processing

CONTOUR CUT Similar to Wood

thin cover sheets and large dimensions treatment conforms rather to wood than to metal

Sawing

with circular, compass or belt saws

Milling

Wood-working machines with adapted tools high cutting speed

Laser & Water Jet cutting

With adjusted focusing (slower than milling)

Stamping & Nibbling

one plane back side and compressed front side

Shearing

With conventional hammer shears

Conventional methods of metal-cutting


SLEEPING CAR RZD – partition walls and compartment doors

Railway Vehicles

Meeting Russian and European fire protection regulations Ready-to-be-installed system Resource-efficient material and full recyclability Ability to withstand up to 200°C→ powder coating

Higher scratch resistance and detergent persistency Weight savings

Reasons for Metawell®


SLEEPING CAR RZD - DOOR

Design: sandwich panel + profiles + mirrow 1. Milling of the sandwich panels 2. Glueing of profiles onto the panel

Metawell®

8

Railway Vehicles

3. Second panel is glued onto profiles 4. Putting into press, where under pressure and heat the glueing process is finished 5. Powder coating of the door, assembly of parts


SLEEPING CAR RZD – partition wall

Design: sandwich panel + profiles + sheet 1. Cut to size Metawell® Aluflex put into a form

Metawell®

9

Railway Vehicles

Aluminium profiles

2. Glue aluminium profiles in pre-milled channels


SLEEPING CAR RZD – partition wall

10

Railway Vehicles

3. Put aluminium sheets with glue on the Metawell® Aluflex and profiles 4. Putting into press, where under pressure and heat the glueing process is finished 5. Powder coating, assembly of the parts

Metawell®


Railway Vehicles

SLEEPING CAR RZD – partition wall – before and after powder coating


Metawell® Aluflex bent transversal to the corrugation

Metawell® Aluflex bent parallel to the corrugation

Metawell®

folded in an edging bench

Metawell® bent round on axis transversal to the corrugation e.g. 4–roller bending machine (only for large bending radii)

SHAPING Metawell® Aluflex

Processing


Designed by PSW / Beamlight Automotive

LONDON SUBWAY seating components

Reasons for the use of Metawell®

high fire protection requirements

stability (against vandalism)

weight savings

Processing

HSC-milling of even panels

folding in an CNC-edging bench

13

Folding


GUMPERT SPORTWAGENMANUFAKTUR “To further improve the passive safety, a crashbox has been integrated into the front section of the Apollo, just like in Formula 1 vehicles.” Metawell® Aluminium crashbox,

partition wall and main-underfloor

Gumpert Apollo

14

Photo: Gumpert Sportwagenmanufaktur


Gumpert Apollo

Processing of the crashbox

CNC-cutting

edging final assembly

In crash situation repeated collapse by folding of the cover sheets between the crests of the corrugation

Functionality of the crashbox


AIDA, TUNNEL-ELEMENTS curved ceiling elements in the corridors of the latest generation of AIDA-cruise liners

Bending

material: Metawell® Aluflex hl 08-03 / H9.8

connection by riveting or bonding

wet painted surface

16

CNC cutting of the Aluflex panelCNC milling of Metawell® Aluflex panel Bending in the formBending in the form

Assemblage of the components

Assemblage of the components

Bended ceiling elements

photo: Ingrid Fiebak

photo: Ingrid Fiebak


Curved Strutures


Curved Strutures


Metawell® Aluflex Bath room Egoist, Foto: Ammonitum

Premium bath


KTM X-BOW

Puristic, Filterless driving experience

Reasoning CFK

high rigidity combined with low weight complex geometry

Initial situation - CFK-underfloor

BUT…. CFK - considerable production effort - high costs!!!

- more favourable basic version?

CFK replaced by Alu!


KTM X-BOW

weight 4.4 kg/sqm CNC- mill cutting of the contour and V-groove for folding aluminium profile as reinforcement

Metawell® Alu hl 05-03-05 hl / H10

ALUMINIUM MAIN-UNDERFLOOR


KTM X-BOW

REAR-DIFFUSOR

two–dimensionally curved geometries are simply to produce milled Metawell® Aluflex is the substructure for bonding with a fitting milled aluminium sheet (0.5 mm) in a form

Metawell® Aluflex hl 05-03 / H9.5 + 0.5 sheet

accurately fitting screw points on the car body gearbox cover (pot gear) special plastic inserts for the screw points of spoilers (peens made of 2 mm aluminium sheet)

DEEP-DRAWN PLASTIC COMPONENTS FOR


KTM X-BOW

REAR-DIFFUSOR ASSEMBLING

upper and lower part of the form made of wooden frames accurate positioning aids for small inserts Metawell® Aluflex and sheet folow without any stress the geometry predetermined by frames final assembly of peens and edge closing after curing of the adhesive

INSERTION OF COMPONENTS INTO THE FORM

2K-PU (SIKA-Force) speed-up of curing time is possible with temperature: e.g. hot air or heating mats

Bonding System


ALUMINIUM MAIN-UNDERFLOOR AND REAR-DIFFUSOR

REASONING ALUMINIUM

only minor increase in weight compared to CFK considerable price advantage by practically same performance

Foto: KTM-Sportcar GmbH

24

KTM X-BOW


FORMING AND PANELING ELEMENTS

CONSTRUCTION OF THE SANDWICH individually finished Aluflex and

processed sheet, perfectly stuck

together, after that final assembly

25

Railway Vehicles


Automotive

VW CALIFORNIA

Holz VW T4

reduction in weight to 1/3, gain of storing space (+60 litre)

stiffness and crash safety automotive approval, recycling EU- old vehicle regulation

Metawell® VW T5

CONSTRUCTIVE DESIGN

26

Foto: Volkswagen AG photo: Volkswagen AG

ALUMINIUM BUILT-IN FURNITURE Metawell® Aluflex cc 05-02 / H4.7 inside coil-coating, bonded to 0.5 mm cover sheet, outside decorative foil decorative transfer adhesive foil applied on 0.5 mm cover sheet edge endings with aluminium U-profile connection technique: screws with spacer blind rivets, bonding, tongue- and groove system


Tailor Made – Big Scale

2 Component–adhesive on bottom sheet

Core layer

Sandwich panel

Sandwich panel + floor covering + profiles


Tailor Made – Big Scale


Thank you for your attention.

www.metawell.com [email protected]

29

Documents

Materials Forum Intelligent-Lightweight Constructionfiles.messe.de/abstracts/57934_Wesolowski.pdfMaterials Forum, HMI 2014 / page 16 AIDA, TUNNEL-ELEMENTS curved ceiling elements in