Increasing Composite Usage In Lightweight Cars By Eliminating "Black Metal" Design

Transcription

1 Increasing Composite Usage In Lightweight Cars By Eliminating "Black Metal" Design Eddie Bernardon, VP Strategic Automotive Initiatives Realize innovation.

2 Specialized Engineering Software Formerly Vistagy, acquired by 2011 Primary focus on Automotive and Aerospace industries Solutions Specialized domains Industry focused End-to-end solutions Multi-CAD, open architecture 300+ global customers Page 2

3 Composite design Tight coupling geometry, material, process GEOMETRY PROCESS MATERIAL Restricted Siemens AG 2015 Page XX-XX

4 Past experience Composite manufacturing technologies Restricted Siemens AG 2015 Page XX-XX

5 The path to cost effective automotive composites Page 5

6 The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 6

7 The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 7

8 Producibility issues Wrinkling Bridging Gap Tool Surface Tool Surface In-plane Micro-buckling In-plane waviness Page 8

9 Basics 2D to 3D shaping of composites 2D 2D 2D Cut Wrinkle Single Curvature Single Curvature Double Curvature Page 9

10 Basics 2D to 3D shaping of composites Page 10

11 Basics 2D to 3D shaping of composites Page 11

12 Formed composite inner hood MATCHED METAL FORMING Page 12

13 Evaluation of producibility on full body ply Page 13

14 Features causing manufacturing issues Compound curvature/steep draft angle cause deformation Page 14

15 Geometric changes modification of draft angle 26 degree draft angle reduction Before After Reducing draft angle significantly improves producibility Page 15

16 Example Black metal design SPLICES Page 16

17 Example Composite friendly design Page 17

18 Comparison of design details Composite friendly vs. black metal design Page 18

19 The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 19

20 Advantage of Composites Metals are Isotropic Composite are Anisotropic (Directional) Quasi Isotropic Laminate (Typical Layup) Page 20

21 Costly material only where needed Topology optimization Principal stress optimization Final TFP part design F F F IFB Institute of Aircraft Design, Stuttgart, Germany Page 21

22 Optimization performance to weight IFB Institute of Aircraft Design, Stuttgart, Germany Page 22

23 Optimization cost to performance IFB Institute of Aircraft Design, Stuttgart, Germany Page 23

24 Cost effective use of expensive material Fiber Spray-up Fiber Spray-up Selective Reinforcement Selective Reinforcement Selectively applied expensive material Same performance/less Cost Courtesy Toho-Tenax Page 24

25 Sprayed Chopped Fiber with Selective Continuous Reinforcements Chopped or short fiber in highly countered areas Continuous reinforcing plies to add stiffness Quantity location of fabric or uni-plies to be verified by CAE analysis Page 25

26 Mix of Materials at the Part Level Injection Molded Eggcrate Stiffener Metal Insert Select Area continuous directional fibers Carbon Fiber Laminate Random Mat Page 26

27 Example Mixed Material Body in White with CFRP - BMW 7 Series Page 27

28 Aerospace Composite Design Boeing 787 Beech Premier, Horizon Business Jets Frame/Stringer/Skin Assembly INNER SKIN OUTER SKIN CORE Page 28

29 The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 29

30 Automotive composites manufacturing technologies Progressive Multi-Stage Forming Double Diaphragm Forming Braiding Blade Forming Page 30

31 grippers move in 3D to p fabric into the desired sh Automotive Forming Tool Technologies grippers fabric grippers air flow or tampers to conform fabric to mold air flow or tampers to conform fabric to mold grippers move in 3D to place Pressure fabric into the desired shape springs Page 31

32 Conclusion 1. Eliminate black metal 2. Use expensive materials only where needed 3. After #1 and #2 apply cost effective manufacturing methods Page 32

33 Thank you Page 33