Use of Continuous Fiber Reinforced Engineering Plastics
Transcrição
Use of Continuous Fiber Reinforced Engineering Plastics
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® VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Laying of tapes (picture AFPT) Plastics in Automotive Engineering Reinforcer Reinforced plastic molding Mannheim, 13.-14. März 2013 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] VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Calculate the right part Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 8 Ultrasim® Predicts Energy Absorption Post Failure Behaviour Force 36 Simulation 30 24 18 12 Experiment 6 0 0 Ultramid® Structure VDI International Congress 10 20 30 40 50 60 70 80 Way Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 11 Automated Tapelaying Available Processes Moving Table with ultrasonic fixation Moving Head with laser welding fixation VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 13 Component Test and Validation Dynamic Test, 5.0 m/s Impactor Speed CAE Break between bolts in both CAE and Test After Test VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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] VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 15 Drop Tower Test Influence of Overmolding Material „Ultramid® 1“ „Ultramid® 2“ specific developed impact modified grade „Ultramid® 2“ „Ultramid® 1“ VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Structures for doors and hatches, even online paintable Mannheim, 13.-14. März 2013 17 Example: Serial Front Seat Pan Opel Astra OPC VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 18 Example: Serial Front Seat Pan Opel Astra OPC Adam Opel AG SeaTcon AG/ SedisTec UG Reinert Kunststofftechnik Maier Formenbau … VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 19 Serial Front Seat Pan Opel Astra OPC Thermoplastic laminate based on Ultramid® PA6 and glass fibers Overmolding material Ultramid® PA6 short glass fiber material VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 20 Ultrasim® for Composites Integration of Relevant Process Steps In-Mold Forming Mechanics Injection Molding Integrative Simulation with ULTRASIM® VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 21 Optimization of Heating Parameters Influence parameters: Material properties (absorption, reflection, thermoconductivity etc.) Type of emitter Emitter control (power profile) Distance, time… VDI International Congress Plastics in Automotive Engineering Trials at Krelus Infrared Mannheim, 13.-14. März 2013 22 In-Mold-Forming and Overmolding mold closing side IR heater laminate in open mold mold injection side Cycle time 70 sec VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 23 Micro CT Testing VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 24 Component Testing m = 25 kg v = 5 - 9 m/s VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 25 Seat Testing Quelle: SedisTec VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 26 Serial Application in Opel Astra OPC Wall thickness 1 mm in laminate 45% weight saving Function integration Cost balance VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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. VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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 VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 29 Future Outlook Design Freedom with New Materials VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 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. VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 31