Design and Manufacturing of a TP Composite Bumper Beam by QSP

Transcription

1 1 Design and Manufacturing of a TP Composite Bumper Beam by QSP JEC world 2017 conference CETIM : Damien Guillon, Clément Callens SNOP : Mickaël Moscardo, Eric Deprun, Georges TEIXEIRA

2 2 Cetim the french innovation maker in mechanics A regional, national and international player: 115 M turn over, 900 employees, 8 sites in France, 44,000 m² of laboratories and platforms 3 subsidiaries in France and North Africa Part of a strategic French R&D network: Covering all topics in the mechanical field with 9 open labs with universities Paving the way to innovative technologies on the whole product s lifecycle A strategy geared around innovation: R&T development & support for more than 4,000 customers per year Acting in standardization committees (216 seats)

3 3 Cetim Composite at a glance: Polymer Material expertise for 40 years +120 PhD, Engineers and Technicians 18M turn over in composite activity Scientific partnership with: ECNantes, ENSCachan, Onera, Imperial College of London Industrial partnership with AFPT for Spide TP and Pinette, Loiretech and Compose for QSP

4 4 SNOP French leading Supplier for Body in White Key Figures 834 M turn over, 5740 employees, 27 manufacturing plants Operating in 11 countries Tons of steels stamped per year 3 main activities: Development and industrialization Manufacturing of BIW subassemblies Design and manufacturing of stamping dies Design and manufacturing of production means : presses and roll forming lines Advanced Engineering : Reason for being part of the project consortium : Weight reduction thought usage of Composite must be anticipated and Product/Process knowledge acquired early.

5 5 TP composite bumper beam project Demonstration of the QSP capability Results of a three years long process development project A one year long part development Design : Specification and validation by SNOP, automotive bumper supplier Optimization methodology to choose the better lay-up configuration Process simulation in input of mold design and product simulation Manufacturing Use of in house pultruded tape Continuous automated production with less than 2 minutes cycle time Testing and costing Real performance and accurate cost analysis

6 6 Design : Use of optimization methodology 5.5 mm thickness with 50% of 0 fiber 5mm thickness with 95% of 0 fiber Optimization results : Thickness and anisotropy in each area

7 7 Design : Process analysis for real composite sizing Use of «drape estimator» : Real fiber orientation in calculation Choice of ply shape to avoid material scrap

8 8 Design : Forming Simulation Use of Hyperform : Validation of process estimation with explicit Finite Element Analysis using fabrics material and inter-ply contact behavior Precise patch shape definition and lay-up position

9 9 Multi-thickness / multi-orientation / multi-material solution Multi-material front end bumper system 1,8kg composite + 0,5kg plastics + 1,3 kg aluminium + 0,1kg rivets = 3,7 kg total weight Composite part lay-up Two versions of patch 1 and 9 : - 4:1 fabrics - UD tape 1,2mm 0 + 0,3mm % mass saving on the steel reference Welding of aluminium part Riveting of the beam sandwiched between aluminium parts

10 10 Specification fulfill! Test case Damner crash 16 km/h Front Pole test crash 25km/h RCAR Bumper crash 10,5km/h ECE42 parking crash 4km/h Towage 750daN (30 /40 ) Target Fmax < 65 kn OK Eabs > 4000 J OK No Body in white damage OK Finit > 20 kn OK No final failure before 200mm calculation OK, test TBC Fmax < 65 kn calculation OK, test TBC Eabs = 3100 J calculation OK, test TBC Enfoncement maxi. = 70 mm calculation OK, test TBC Flèche < 30mm OK No damage OK No damage OK Sufficient Stiffness OK

11 11 General possibilities of the QSP (Cetim s pilot line) THERMOFORMING & OVERMOULDING To add a maximum value intra-mold & get a netshape part RAW MATERIALS Fibers & Thermoplastic Any other organo sheets or tapes TP PULTRUSION To create semi-products with a low cost and high speed of production HIGH SPEED CUTTING To cut all patches needed for the multi-thickness preform HIGH SPEED TRANSFER < 5sec PREFORM ASSEMBLY To make an automated assembly of a multilayer netshape preform < 1min FAST HEATING Combining conduction & High-Speed IR ovens for multi-thickness preforms

12 12 From the raw material to the preform Pultrusion of the main reinforcement 85% of the part s mass at lower cost The right width to avoid scrap The optimized thickness (1,2 mm) and 50% volume of fibre content. 0% of scrap thanks to rectangular cut patern 7 8 1a 1b 1c 1d 9d 9a 9b 9c Cut patern of the thin CELSTRAN tape (305 mm standard width) Patch 1 Patch 9 Patch 6 Cut patern of the pultruded tape (230 mm specific width)

13 13 From the preform to the part 95 seconds heating time (5,7mm maximum thickness) Temperature homogeneity (deviation<20 C) thanks to combined ovens Forming, holes drilling and overmoulding in one step

14 14 From the preform to the part

15 Force (kn) Testing «Parking» low velocity ECE 42 crash test No damage displacement (mm) Test -40 simulation

16 Force (kn) Testing Pole test 36km/h No final breaking before 200mm of intrusion, thanks to a progressive failure displacement (mm)

17 17 Economical summary Step Price Composite material (prepreg price 3 /kg) 5,7 Cutting 0,6 Plastic material (compound price 3 /kg) 1,2 QSP 3,4 Composite beam total 10,9 Aluminium parts 11,2 Final assembly 1,8 Total system cost 23,9 Detailed cost analysis according to automotive standard have been made Function integration needed to enhance the performance/cost ratio.

18 18 Next step : Towards an integrated composite crashbox

19 19 Key Benefits of QSP Bumper beam Multi-thickness/multi-orientation preform - 20% of composite mass compared to a constant thickness design Proven and efficient industrial process 300,000 part/year capacity demonstrated on CETIM pilot line With 2 cavities on a 500T press Acceptable over-cost (comparable with the one for aluminium solution) Prepreg price of 3 /kg possible with a 3 meters/minute pultrusion process Freedom in material choice and 0% scrap design Ability to mix pultrusion, fabric sheet, thin tape, and to integrate local carbon patches Come and visit us : Composites in action - Hall 5a - Stand M81