Increasing Composite Usage In Lightweight Cars By Eliminating "Black Metal" Design Eddie Bernardon, VP Strategic Automotive Initiatives Realize innovation.
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
Composite design Tight coupling geometry, material, process GEOMETRY PROCESS MATERIAL Restricted Siemens AG 2015 Page 3 2015-XX-XX
Past experience Composite manufacturing technologies Restricted Siemens AG 2015 Page 4 2015-XX-XX
The path to cost effective automotive composites Page 5
The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 6
The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 7
Producibility issues Wrinkling Bridging Gap Tool Surface Tool Surface In-plane Micro-buckling In-plane waviness Page 8
Basics 2D to 3D shaping of composites 2D 2D 2D Cut Wrinkle Single Curvature Single Curvature Double Curvature Page 9
Basics 2D to 3D shaping of composites Page 10
Basics 2D to 3D shaping of composites Page 11
Formed composite inner hood MATCHED METAL FORMING Page 12
Evaluation of producibility on full body ply Page 13
Features causing manufacturing issues Compound curvature/steep draft angle cause deformation Page 14
Geometric changes modification of draft angle 26 degree draft angle reduction Before After Reducing draft angle significantly improves producibility Page 15
Example Black metal design SPLICES Page 16
Example Composite friendly design Page 17
Comparison of design details Composite friendly vs. black metal design Page 18
The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 19
Advantage of Composites Metals are Isotropic Composite are Anisotropic (Directional) Quasi Isotropic Laminate (Typical Layup) 0-45 +45 90-45 +45 0 Page 20
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
Optimization performance to weight IFB Institute of Aircraft Design, Stuttgart, Germany Page 22
Optimization cost to performance IFB Institute of Aircraft Design, Stuttgart, Germany Page 23
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
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
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
Example Mixed Material Body in White with CFRP - BMW 7 Series Page 27
Aerospace Composite Design Boeing 787 Beech Premier, Horizon Business Jets Frame/Stringer/Skin Assembly INNER SKIN OUTER SKIN CORE Page 28
The path to cost effective automotive composites 1. Eliminating black metal design 2. Cost effective material selection 3. Utilize cost effective manufacturing Page 29
Automotive composites manufacturing technologies Progressive Multi-Stage Forming Double Diaphragm Forming Braiding Blade Forming Page 30
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
Conclusion 1. Eliminate black metal 2. Use expensive materials only where needed 3. After #1 and #2 apply cost effective manufacturing methods Page 32
Edward.Bernardon@siemens.com Thank you Page 33