Simulating Structural Composite Hybrid Parts made … HiAnt ® Simulation SPE Automotive Composites Conference & Exhibition September 11-13, 2012 Agenda Overview to Lanxess Corporation

Simulating Structural Composite Hybrid Parts made from Continuous Fiber Reinforced Thermoplastics

Vasant Pednekar,

SPE ACCE, Sept. 11-13, 2012

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SPE Automotive Composites Conference & ExhibitionSeptember 11-13, 2012

Agenda

Overview

to Lanxess Corporation and High Performance Materials

Introduction: Plastic-Metal

Hybrid Technology

Continuous

Glass Fiber Composite

Hybrid Technology

Mechanical

and Process

simulation

for

composite

sheets

Integrative simulation

of hybrid composite

parts

Validation: Testing

and Simulation

Conclusion

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LANXESS is one of Germany’s most important providers of polymers and chemicals

Employees worldwide

Global orientation

approx. 16,500

48 production sites worldwide

Performance PolymersAdvanced Intermediates Performance Chemicals

Portfolio

Sales in the year 2010 EUR 7.120 bn

Sales in the year 2011 EUR 8.775 bn

Facts & Figures

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High-performance materials and high-end engineering know-how at its best

Expertise for all stages of advanced component development

Tailored high-tech plastic

compounds

Smart solutions energized by LANXESS – innovative, flexible, fast

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Plastic-Metal Hybrid Technology

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Plastic-Metal hybrid technology Plastic provides full performance

Lightweight structures

(thin wall thickness)

preference for denting

or buckling

The structure can be supported with small

forces, that are carried by the plastic ribs

F1 F2→ →

Fplastic Fplastic→ →

F2 >> F1→ →

sheet

metal

support

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Plastic-Metal hybrid technology The best from two worlds

Metal•

high strength and stiffness

•

ductile behavior•

low CLTE•

Good deep drawing

Hybrid

•

reduced tendency to buckling of thin wall metal structures

•

high energy absorption•

low part weight by thin walls•

high integration of functional elements

•

high precision in production and use

•

high temperature resistance (e-coating capability)

•

design freedom•

good impact strength and stiffness

•

low viscosity•

low density•

resistance against oil, grease and detergent

Polyamide 6 GF

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Plastic-Metal hybrid technology How hybrid is designed

Rib Pattern

Overmolded Edge

Connecting Spots

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Plastic-Metal hybrid technology History

First prototype

(1989) First serial

parts

(1997/98)

Recent

serial

parts

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More than 50 Mio. produced hybrid-frontends.More than 70 different series applications in automotive.

Plastic-Metal hybrid technology History

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HiAnt® Technology: Continuous Glass Fiber Composite Hybrid Technology

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Hybrid technology Introduction: Continuous Glass Fiber Composite Sheet

Hybrid composite

parts

Low weight

(density

e.g. 1.8 kg/dm³)

Good mechanical

properties

No corrosion, simple recycling

No investment

for

additional tools

Composite

sheets

-

What‘s

that?

Thermoplastic

matrix

materials

(PA)

Reinforced

with

woven

or

non-crimp

fabrics

Continuous

fibers

(fiber length

= part

length)

Glass, carbon

or

aramid

fibers

(also hybrid)

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Hybrid technology Composite sheets: One shot processing

Demolding

IR emitterHeating

> TM

Forming

(and trimming) in theinjection

molding

tool

…

… and subsequent

moldingof e.g. a rib

structure

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Hybrid technology Examples made by one shot processing

Door

impact

beam(demonstrator)

Steering-column

holder(demonstrator)

Tepex® + Durethan®

BMBF project

„SpriForm“

in cooperation

withBond Laminates, Audi, KraussMaffei, Jacob Composite, IVW


Projekt in cooperation

withBond Laminates, Engel, LKT, NMF, Siebenwurst

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Hybrid technology Composite sheets: Simulation, a KEY to success

Hybrid composite parts New material (composite sheets) New process (one shot molding)

The “Access”Simulation is critical for ... ... mechanical component behavior ... processing (forming + molding)

The benefits New technology in CAE Shortened development times Reduced development costs Parts designed to the limits

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Main mechanical

characteristics

Anisotropy

Non-linearity

Strain

rate dependency

Difference

tension

/ bending

Difference

tension

/ compression

Damage

/ Failure

/ Breakage

Rotation of fiber directions

/

Non-orthogonal

fiber directions

Temperature

dependency

Moisture dependency

Tensile

tests

in different directions

Tepex®

dynalite

102-RG600(x)/45%

Strain [%]

Stre

ss [M

Pa]

0 °7,5 °15 °22,5 °30 °37,5 °45 °

Hybrid technology Composite sheets: Simulation, a Challenge

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Hybrid technology Composite sheets: Simulation, a Challenge

Challenge:No suitable

material modelthat

covers

all relevantmechanical

characteristicsavailable

in commercialsimulation

codes

Solution:Development

of a newmaterial model

forcomposite

sheets

andimplementation

into

acommercial

simulation

code

Main mechanical

characteristics

Anisotropy

Non-linearity

Strain

rate dependency

Difference

tension

/ bending

Difference

tension

/ compression

Damage

/ Failure

/ Breakage

Rotation of fiber directions

/

Non-orthogonal

fiber directions

Temperature

dependency

Moisture dependency

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Hybrid technology Validation of the material model

Tensile

tests

0° Tensile

tests

45°

Tepex®

dynalite

102-RG600(x)/45%

Strain [%]

Stre

ss [M

Pa]

M qsM 1 1/sM 10 1/sM 100 1/sS qsS 1 1/sS 10 1/sS 100 1/s

Strain [%]

Stre

ss [M

Pa]

M qsM 1 1/sM 10 1/sM 100 1/sS qsS 1 1/sS 10 1/sS 100 1/s

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Hybrid technology Composite sheets: Processing and Forming mechanisms

Composite

sheet

processing

Fiber orientation

known Only

simple geometries

„Folding“

Fiber orientation

not

known Complex

geometries

possible

„Forming“

Forming

mechanisms

Metal sheets: Plastic

deformation

Adeformed

> Aundeformed

Wall thickness

distribution

Composite sheets: Shear

(„Trellis“

effect)

Adeformed

Aundeformed

Fiber orientation

distribution

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Forming / Draping Simulation: Material testing - Picture frame test for Forming test

Test setup

and simulation

model

F→

Measurement

results

TM

222 °C

Tepex®

dynalite

102-RG600(x)/45%Measurement

implemented

at LKT, Friedrich-Alexander-Universität Erlangen-Nürnberg

Shear angle [°]Fo

rce

[N] 210 °C

216 °C218 °C220 °C222 °C

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Forming / Draping Simulation: Application example - “Mouse bath tub”

0 °

22,5 °

45 °

+ 55 °

- 55 °

Forming

simulation Forming

behavior

orientation

ofcomposite

sheet

change

offabric

angle

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Forming / Draping Simulation: Application example - “Mouse bath tub”

0 °

22,5 °

45 °

+ 55 °

- 55 °

Forming

simulation Forming

behavior

orientation

ofcomposite

sheet

change

offabric

angle

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Composite Sheet Simulation: Process to simulate Forming for Composite Sheets

Formingproperties

Formingsimulation

Fiberorientation

Mapping

Material modelcomposite

sheet

Mechanicalproperties

HiAnt® material data

HiAnt® simulation

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Short Fiber Composite Simulation: Fiber orientation distribution in injection molded parts

Skin layer: random

orientation

Shear

layer: ll

to flow

direction

Core

layer: to flow

direction(with

fountain

flow)

Orientation due to melt flow Result: Anisotropic

layer

structure

V

V

The fibre orientation is different over the part and in thickness direction !

Injection

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Composite Sheet Simulation: Process to set up simulation for structural part

Formingproperties

Formingsimulation

Fiberorientation

Mapping


sheet


Moldingproperties

Moldingsimulation

Fiberorientation

Mapping

Material modelDurethan®



HiAnt® simulation

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Composite Sheet Simulation: Verifying Bond strength of hybrid composite structures

T-joint

plate

(overmolded

composite

sheet) Testing

of bond

strength

Heating

of the

composite

sheet Injection

molding

parameters Flow

length Material …

Effects

on bond

strength

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HiAnt® Simulation: Simulating structural composite hybrid parts

Formingproperties

Formingsimulation

Fiberorientation

Mapping


sheet


Moldingproperties

Moldingsimulation

Fiberorientation

Mapping

Material modelDurethan®


Interfaceproperties

Composite Sheet Simulation: Process to simulate structural composite hybrid parts


HiAnt® simulation

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Hybrid technology Validation: Door impact beam (demonstrator)

a

b

cc

b

a Displacement [mm]

Forc

e [k

N]

Measurement Simulation

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Hybrid technology Validation: Bumper beam (demonstrator)

Failure

in the

composite

sheet

mDolly

mPendulum

v0


BMBF project

„SpriForm“

Time [ms]Fo

rce

[kN

]


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Hybrid technology Validation: Upper beam of a frontend (prototype)

Two

different Lanxess rib

materials: Durethan

BKV30 H2.0 901510 Durethan

DP BKV60 H2.0 EF 900116

Part testing

setup

DurethanBKV30

DurethanBKV60 EF


Project in cooperation

with

Faurecia

Displacement [mm]

Forc

e [N

]


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Summary

Plastic-metal-hybrid technology has proven its capabilities for more than 10 years in many different applications

The combination of CFTs

and injection molding leads to hybrid parts with an excellent strength and stiffness. Additionally –

or as an alternative -

lightweight design can be archived and functions can be integrated

The know-how to simulate the material behavior of CFT and their overmolding is crucial for a successful product development

Dr.-Ing. Marcel BrandtCAE Development

/ Part Testing

LANXESS Deutschland GmbH

SCP-GPAD Customer

Engineering Services

41539 Dormagen, Bldg. F45

Phone: +49 2133 / 51 -

29664

Fax: +49 2133 / 51 -

29671

Mobile: +49 175 / 31 -

29664

E-Mail: [email protected]

Internet:

http://www.lanxess.com

Thank You for Your Attention

Vasant PednekarLANXESS Corporation

111, RIDC Parkwest Dr,

Pittsburgh, PA - 15275

Tel.: +1 412 8093557

Mobil: +1 412 5085142

Fax: +1 412 8091067

E-Mail: [email protected]

Internet : http://www.lanxess.com

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Safe harbour statement

This presentation contains certain forward-looking statements, including assumptions, opinions and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of the company to differ materially from the estimations expressed or implied herein. The company does not guarantee that the assumptions underlying such forward looking statements are free from errors nor do they

accept any responsibility for the future accuracy of the opinions expressed

in this presentation or the actual occurrence of the forecasted developments.

No representation or warranty (express or implied) is made as to, and no reliance should be placed on, any information, including projections, estimates, targets and opinions, contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and, accordingly, none of the company or any of its parent or subsidiary undertakings or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the

use of this document.

Documents

Simulating Structural Composite Hybrid Parts made … HiAnt ® Simulation SPE Automotive Composites Conference & Exhibition September 11-13, 2012 Agenda Overview to Lanxess Corporation