Use of Continuous Fiber Reinforced Engineering Plastics

Transcrição

Use of Continuous Fiber Reinforced Engineering
Plastics: The Seat Pan of the Opel Astra OPC
Jörg Schnorr, BASF SE, Dr. Ralf Langendorf, Adam Opel AG, Rüsselsheim, Jordan Kurikov, BASF SE, Ludwigshafen
VDI International Congress
Plastics in Automotive Engineering
Mannheim, 13.-14. März 2013
New Applications in Automotive with
Fiber Reinforced Engineering Plastics
Semi-structural parts
Ultramid®
Short fibers
Structural parts
Ultramid® Structure
Long fibers
Polyamide with continuous fibers
(Tape/Laminate + Overmolding)
Developments supported by simulation tool ULTRASIM®
2
Continuous Fiber Reinforcement
of Injection Molded Parts
Types of Semi Finished Products
Thermoplastic
laminate
Organosheet
(picture IVW)
Heating
One Shot Draping
and Overmolding
Reinforced plastic
molding
UD
Tape
Pultruded Tape
fully impregnated
Laying of tapes
(picture AFPT)
Reinforcer
Reinforced
plastic molding
3
Potential of continuous fiber reinforced plastics
Carbon vs. glass fibers --- Stiffness vs. Strength
140
All materials 50 Vol.-% fiber content
120
UD-Tapes CF
[GPa]
Stiffness
Stiffness [GPa]
100
80
Al
60
Laminates 0/90 CF
Mg
40
Source: Fiberforge
20
UD-Tapes GF
PA-GF50
Laminates 0/90 GF
PA-GF30
0
0
200
400
600
800
1000
1200
1400
1600
1800
Strength [MPa]
Strength
[MPa]
4
BASF and TenCate: Strategic Alliance for
Thermoplastic Automotive Composites
Joint development and production of
thermoplastic composites:
UD-tapes and laminates
 BASF: Know-how in research, production
and formulation of thermoplastic resins
 TenCate Advanced Composites:
Expertise in composite manufacturing
 Advanced tapes and laminates…
 For structural automotive parts
(car body, chassis)
 Focus on mass production
5
Integrative Simulation ULTRASIM®
for Continous Fiber Reinforced Plastics
Process
Measurement
Draping / Molding
Material
Part
BASF approach: full ULTRASIM®
prediction and design level for
continuous fiber reinforcement
6
Material Characterization for ULTRASIM®
Laminates and Tapes
 Tensile Test

Orientation

Testing Speed

(Wallthickness)

Humidity
 3 Point Bending
 Puncture Test
 Compression Test
 Sheartest
 Adhesion of Ribs
 Draping
Drapiereigenschaften
IVW, Kaiserslautern
7
Ultrasim® Helps to Optimize the Design of
Plastic Parts
ULTRASIM®
Material modelling Integrative Simulation





Anisotropic
Nonlinear
Strain-rate sensitive
Tension-compression asymmetric
Failure modeling
CAE Methods +
Mathematical Optimization
 Process simulation
 Mechanical simulation
 Mathematical optimization
(parameter, shape, topology)
Calculate the part right
Calculate the right part
8
Ultrasim® Predicts Energy Absorption
Post Failure Behaviour
Force
36
Simulation
30
24
18
12
Experiment
6
0
0
Ultramid® Structure
10
20
30
40
50
60
70
80
Way
9
Which Type of Semi Finished Material?
Tapes
Parts with areas of highest local
anisotropic load distribution
e.g. front seat backrests
Laminates
predominantly closed areas, mechanical
load rather evenly distributed
e.g. seat pans, rear seat backrests,
vehicle floors
10
Example: Prototype-Seat Backrest with
overmolded Tape Reinforcement
Injection
molded PA6
UD-Fiber
reinforcement
Overmolded in
injection molding
process
UD- Fiber reinforcement in high loaded zones
Injection molding material in zones of medium load and functional integration
11
Automated Tapelaying
Available Processes
Moving Table
with ultrasonic fixation
Moving Head
with laser welding fixation
12
Consolidation of Tapes
Microscopy und Micro-CT
glass fibers
before Consolidation
matrix: PA6 Ultramid®
after Consolidation
6-layers: 0°/90°/0°/0°/90°/0°
thickness 0,25mm each
60 weight-% glass fibers
13
Component Test and Validation
Dynamic Test, 5.0 m/s Impactor Speed
CAE
Break between bolts in both
CAE and Test
After Test
14
Drop Tower Test
Influence of Fiber Length
Test Temperature 23°C
700
PA6 GF50 23°C
Ultramid®
PA6 LGF40
23°C
Ultramid®
Structure
Ultramid®
+ Reinforcer
PA6 CFRT
23°C
600
Energy [J]
500
400
300
200
100
0
0
10
20
30
40
50
60
70
Time [ms]
15
Drop Tower Test
Influence of Overmolding Material
„Ultramid® 1“
„Ultramid® 2“
specific developed
impact modified grade
„Ultramid® 2“
„Ultramid® 1“
16
Further Potential in Vehicles
Structural
Inserts (A-, B-,
C-Pillar, Roof
Frame…)
Roof Cross
Member
Cross Car
Beam
Crash
Extensions
Fire Wall
Battery
Integration
Frontend
Structural
Floor
Structures for doors
and hatches,
even online
paintable
17
Example:
Serial Front Seat Pan Opel Astra OPC
18
Example:
 Adam Opel AG
 SeaTcon AG/
SedisTec UG
 Reinert
Kunststofftechnik
 Maier Formenbau
 …
19
Thermoplastic laminate based on
Ultramid® PA6 and glass fibers
Overmolding material Ultramid®
PA6 short glass fiber material
20
Ultrasim® for Composites
Integration of Relevant Process Steps
In-Mold Forming
Mechanics
Injection Molding
Integrative Simulation with ULTRASIM®
21
Optimization of Heating Parameters
Influence parameters:
 Material properties (absorption,
reflection, thermoconductivity etc.)
 Type of emitter
 Emitter control (power profile)
 Distance, time…
Trials at Krelus Infrared
22
In-Mold-Forming and Overmolding
mold closing side
IR heater
laminate in open mold
mold injection side
Cycle time 70 sec
23
Micro CT Testing
24
Component Testing
m = 25 kg
v = 5 - 9 m/s
25
Seat Testing
Quelle: SedisTec
26
Serial Application in Opel Astra OPC
 Wall thickness 1 mm
in laminate
 45% weight saving
 Function integration
 Cost balance
27
Conclusion

Thermoplastic laminates can be used in serial production
processes for the automotive industry.

Properties of both semi finished material and overmolding
material determine part performance.

ULTRASIM® enables fast development of overmolded
continuous fiber parts even in crash relevant applications.
Hereby strengths of these materials can be used by far better
than with standard methods.

Interesting weight and cost results can be reached in
automotive seats.
28
Feedback
„…die nahezu
perfekten,
18-fach
einstellbaren
Schalensitze“
http://www.automotor-undsport.de/fahrberichte/
opel-astra-opcflitzlicht-gewitter-aufder-nordschleife5035812.html
download am
21.11.2012
29
Future Outlook
Design Freedom with New Materials
30
The information and data given here are based on our current knowledge and experience. This does not relieve the
purchaser of our products from incoming inspection. The information and data do not describe the suitability of the
product for a specific application. Composition - and durability statements - as well as any other statements are not to
be considered as a warranty.
The values contained herein are based on analysis/testing of laboratory test specimens and represent data that fall
within the normal range of properties for natural materials, unless stated otherwise. Colorants and additives may alter
properties.
This information is provided as a service for comparative purposes only and in no way constitutes any product
specification or the like. For component design the data contained herein are applicable as guideline only.
31

Use of Continuous Fiber Reinforced Engineering Plastics

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