UTILIZING ADVANCED COMPOSITE TECHNOLOGY

Transcription

1 SEPTEMBER 25 TH 2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY Beispielbild passendes Bild einfügen Paul Thom, Sales and Product Manager Hydraulic Press Systems Mobile Dipl.-Ing. Patric Winterhalter, Product Manager Composites 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 1

2 UTILIZING ADVANCED COMPOSITE TECHNOLOGY AGENDA COMPANY MOTIVATION PROCESSES AND REQUIREMENTS ALWAYS THE RIGHT SOLUTION SCHULER COMPOSITE PRESSES COMPOSITES ALLIANCE FUTURE TREND PARTNERSHIPS WITH R&D FACILITIES 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 2

3 SCHULER AT A GLANCE Technological and global market leader in the forming industry Annual sales 1,200.0 mio. with 6,700 employees Top-tier customers: Car manufacturers and their suppliers, packaging, household equipment, aerospace, minting Global footprint: Several sales and service locations in the US Extract customer references 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 3

4 MOTIVATION UTILIZATION OF LONG FIBER REINFORCED PLASTICS Fiber reinforced plastics Tremendous weight saving potential Integration of functions and/ or complex shapes Reduced mold cost ideal for low to mid volumes Using compression molding processes with a press Not too low volumes (> 1,000) Automatic and economical production feasible High performance parts (with long and endless fibers) Lightweight potentials of materials Source: Audi AG August UTILIZING ADVANCED COMPOSITE TECHNOLOGY 4

5 OVERVIEW OF COMPOSITE RAW MATERIALS Fibres Aramid Carbon Glas Metal Plastic Mineral Natural. Reinforcement Shortfibre Longfibre Endlessfibre Resins Ceramic Thermoset Thermoplastic Elastomer Metalic Concrete... 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 5

6 OVERVIEW COMPOSITE PRODUCTION PROCESSES Thermoset matrix SMC / C-SMC Thermoplastic matrix GMT / LFT / LFT-D Long fiber < 50 mm Hybrids HP-RTM / wet-rtm / prepreg Organic sheet / Tape Endless fiber > 50 mm 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY Source: BMW and BASF 6

7 DIFFERENT JOBS DIVERSITY OF PROCESSES Thermoset Thermoplastic General Requirements Random fiber orientation Dedicated fiber orientation Uniform wall thickness of parts Dwell time & accurate Position and Parallelism control High mold opening force & mold temperature control Variety of die functions & all in one single press operation resin injection mold evacuation high slide speed short closing time continuous slide motion fast pressure build-up 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 7

8 EXAMPLE - SCHULER CLASSIC PRESS LARGE SCALE HP-RTM MANUFACTURING LINES Eleven production lines for HP-RTM process Classic design of press Serial production with 25,000 cars per year Approx. 6 min cycle time Automatic tool change Source: BMW 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 8

9 DIFFERENT JOBS DIVERSITY OF PROCESSES Thermoset Thermoplastic General Requirements Random fiber orientation Dedicated fiber orientation Uniform wall thickness of parts Dwell time & accurate Position and Parallelism control High mold opening force & mold temperature control Variety of die functions & all in one single press operation resin injection mold evacuation high slide speed short closing time continuous slide motion fast pressure build-up 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 9

10 THE NEW SCHULER COMPACT PRESS DESIGN MAIN CHARACTERISTICS Reduced building costs Use of existing building with reduced height Highest output Minimal parts rejection Flexibility Presses capable for all processes Reduced operating costs Energy efficient production Compact Schuler press 36,000 kn with 3.6 x 2.4 m platen surface 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 10

11 HIGH QUALITY PARTS NEED HIGH PRECISION PRESSES HIGH POSITION AND PARALLELISM ACCURACY Crosswind Position accuracy 0.05 mm equal to 1 hair Parallelism accuracy 0.05 mm equal to 1 hair 90,000 kg 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 11

12 MULTIFUNCTIONAL HYDRAULIC COMPACT PRESS USED ALL OVER THE WORLD NCC AZL IACMI OEM National Composite Center Bristol, England CHAPU x2.4 The Aachen Center for Integrative Lightweight Production Aachen, Germany CHAPU x1.8 Institute for Advanced Composites Manufacturing Innovation Detroit, USA CHAPU x2.4 R&D Department and series production Republic Korea CHAPU x2.4 In use since 2014 In use since 2017 In use since 2017 Installation right now 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 12

13 TURN-KEY COMPOSITE MANUFACTURING LINES Concentration of FRIMO s and Schuler s know-how and experience in the processing of FRP The Alliance provides customized turnkey solutions for manufacturing of light-weight components in series production delivered by a single source Material Feeding Cutting Heating Presses Resin Injection 3D Cutting Handling Moulds 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 13

14 SAMPLE THERMOSET APPLICATION LARGE SCALE HP-RTM MANUFACTURING LINE Material Cutting Alignment Heating Preforming 3D Cutting RTM Injection 3D Cutting Postprocess 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 14

15 TREND OF HYBRID PART MANUFACTURING COMBINATION OF HOT STAMPED STEEL AND FIBER REINFORCED PLASTICS Hot stamping of steel Fiber reinforced plastics Hybrid parts = Schuler can deliver turnkey systems for hot stamping, composite and hybrid manufacturing We can develop hybrid parts together with you 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 15

16 SCHULER MEMBERSHIPS WE ARE MEMBERS IN MANY IMPORTANT RESEARCH INSTITUTES WE ARE MAKING THE RESULTS OF RESEARCH RELEVANT FOR YOUR DAILY PRODUCTION Consulting along the whole process chain (material, process, quality control, joining, etc.) Joint product and process development Prototyping and process start-up Production capacity available Our capability to innovative is the main pillar of our market success Source: NCC 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 16

17 SUMMARY UTILIZING ADVANCED COMPOSITE TECHNOLOGY There is a motivation using composites in the automotive industry Equipment of Schuler for R&D and high volume production well proven over many years Schuler offers high precision presses for high quality parts Innovative compact press with highest output, great flexibility and reduced operating costs Turnkey composite manufacturing solutions in collaboration with Composites Alliance partner Frimo Partnership with R&D facilities all over the world to support our customers Thank you for your attention! 9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 17