LaTCh II Project Lightweight Thermoplastic Composites 2018-11-06 Pedro Mimoso Composite Process Engineer INEGI
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
LaTCh II Project Lightweight Thermoplastic Composites
2018-11-06
Pedro MimosoComposite Process EngineerINEGI
http://europa.eu/rapid/press-release_MEMO-17-4243_en.htm
Project Context
MOTIVATIONS
European Commission CO2 emissionsstandards for cars and vans in EU for thenear future
Project Context
MOTIVATIONS
Mechanical performanceAn unmatched weight/strength ratio to meet2020regulations
Energy Consumption Weight
http://multibriefs.com/briefs/exclusive/automotive_lightweighting_trend_2.html#.W9LLDWhKiUk
Project Context
MOTIVATIONS
Consortium
LaTCh Project Consortium
Automotive Components
Product Engineering
Tool Engineering | Injection Molding
Research and Technology Organization
Consortium
LaTCh Project Consortium
Automotive Components
Product Engineering
Tool Engineering | Injection Molding
Research and Technology Organization
Consortium
LaTCh Project Consortium
Automotive Components
Product Engineering
Tool Engineering | Injection Molding
Research and Technology Organization
Consortium Projects
LaTCh Projects Births
Stamp forming Injection
Replacement of steel
Maintaining/Improving mechanical performances
Lightweight Reduction of energy
consumption
LaTCh ProjectsLightweight Thermoplastic Composites
Technologies associated with unidirectional continuous fiber thermoplastic composites
Steel
Composite
Automotive Components
Product Engineering
Tool Engineering | Injection Molding
Research and Technology Organization
Consortium Projects
Lightweight Composites
PROJECT IMPLEMENTATION PLAN
A2 – New constructive solutions and associated processes Leader: INEGI
Generation and selection of the concept
Selection and characterization of the materials
Manufacturing process and industrial means
Analysis of the technical-economic viability of the solution
A1 – Preliminary studies Leader: MCG
Ongoing needs on the automotive sector
Identification of process-oriented
products
Product selection and Benchmarking
Specifications / Product RequirementsDefinition of validation tests
A5 – Prototype manufacturingLeader: Moliporex
Validation tests
Productive processes implementation
Prototype production
Analysis and correlation of results with simulations (injection / stamping)
A7
–P
roje
ct m
anag
emen
tLe
ade
r: M
olip
ore
x
A6 – Promotion and dissemination of resultsLeader: MCG
A3 - Product developmentLíder: CadFlow
A4 – Process developmentLeader: INEGI
Interfaces definition
Product modelling - CAD
Structural Analysis - CAE
Specification and implementation of monitoring and control means
Optimization of the stamping process parameters
Process simulation (injection / stamping)
Development and construction of one-shot process equipment
Design and manufacture of the tools
Consortium Projects
Lightweight Composites
Short cycle times
One-shot process
Hybrid structural component
Less resources
LightweightThermoplasticComposites
LaTCh ll Project
Final geometry part – no need of subsequent cuts or finishes
MacPherson control Arm
Project Development
Lightweight Composites
Requirements
Speed bumpforce
Project Development
Lightweight Composites
CAE – Validating requirements on Abaqus ®
a) VonMises criteria applied on injection-moulded thermoplasticb) Hashin criteria applied on the unidirectional carbon fiberc) displacement analysis on the injection-moulded thermoplastic
a)
b)
c)
Project Development
Lightweight Composites
Getting the final part
Project Development
Process Validation
AniForm®
Results of the simulation of the injection PA6 RGF 30%
MoldFlow ®
Project Development
Process implementation
Blank production for stamping and overmolding
Project Development
Stamp forming/overmolding Cell
Project Development
Lightweight Composites
The final part
Project Achievements
LaTCh ll
Testing and monitoring
Displacement (mm)
Load
(N
)
Displacement (mm)
Load
(N
)
Project Achievements
LaTCh ll
Testing and monitoring
Load
(kN
)
Time (s)
Dis
pla
cem
ent
(mm
)
Displacement minimum load Displacement maximum load Displacement medium load
OEM and First Tiers market
A company of the VANGEST group
A company of the VANGEST group
Research and Technology Organization
Lightweight Thermoplastics Composites
LaTCh II
Project Achievements
LaTCh ll
The results on the brake and acceleration tests were in accordance with the requirements and the previous simulations, proving the validation of the product.
The results on the fatigue lifecycle tests did not show any structural failure and the aging also did not cause degradation in the performance of the parts, in both the static tests of braking and acceleration.
PRODUCTComposite
Component
Steel
Component
Mass 1,115 kg 2,0 kg
Gain 44%
Project Achievements
LaTCh ll
OEM and First Tiers market
A company of the VANGEST group
A company of the VANGEST group
Research and Technology Organization
Lightweight Thermoplastics Composites
Improvements on the process:–> cycle times–> resources
Improvement in the part complexity: –> hybrid components successfully achieved–> best adhesion
The main objective on thereduction of the number ofsteps, envisioning the one-shotprocess was successfullyachieved.
Project Achievements
LaTCh ll
Project Dissemination
Composites Europe 2018
Hall 9 - C60h
Questions?
Thank you
Related Documents
