helena simmonds - research and development of composites at … · 2018-10-03 · epoch hvm...
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Research and Development of Composites at WMG in High Volume Automotive Applications
Helena Simmonds,WMG, University of Warwick
Automotive Composites Research Centre
Professor Ken KendallHead of Structural Composites Group
Opened January 2015
20 staff including research fellows, project engineers and technical staff.
State of the art facilities focussed on structural composites for high volume automotive applications
PROCESS SIMULATION
MATERIAL CHARACTERISATION
PROCESS AUTOMATION
COMPLEXPREFORMING
‐ Dry fibre‐ Prepreg
COMPRESSIONMOULDING
‐ SMC‐ Prepreg
‐ Thermoplastic‐ Hybrid
RESIN TRANSFERMOULDING
‐ HP‐RTM
The CLASS ProjectCo‐funded by Innovate UK on the IDP11 “Adapting Cutting Edge Technologies” call24 month projectLed by Ford Motor Company and partnered by WMG (University of Warwick), Gestamp (Autotech UK) and GRM Consulting.
Tieblade
Knuckle
Tieblade / Knuckle Suspension Component
Initial expectations were to convert from a multi‐piece steel design to a single piece carbon fibre SMC material design
Project Aims and ObjectivesCost
Cost per vehicle must not increase by more than $30Material costs are high for Carbon Fibre Composites
Weight ReductionSteel component weights 6.15kgTarget weight of 3.15kgThis results in a target weight reduction of 49%
High Volume Manufacturing
Need to prove technology for automotive sectorCycle times under 5 minutesFord Focus ST used which has an annual volume of 25,000 to demonstrate technology
Engineering RequirementsStrength Load casesStiffness Load casesDesign Verification Process
Hybrid Design for Prototype Manufacture
PREPREG AND SMC AND STEELPrepreg tieblade running length of blade to manage stiffness requirements.SMC materials used to meet geometry requirements whilst reducing weightSteel insert employed to increase strength in knuckle area especially at the clevices.
STEEL INSERT CHALLENGESDelamination at steel / composite interface due to differing expansion on heating
Honeycomb insert geometry to reduce weight and thermal mass of insert
Reduced inter‐laminar shear strength at interface
Steel inserts were coated to improve adhesion between materials
Manufacturing Process
AutomatedPrepreg Ply Cutting
RoboticPick & Place
Preform and Trim
SMC Cutting
Coated Steel Insert
Compression Moulding
Compression Moulding MachiningMachining
Manufacturing at WMG
PICK AND PLACERobot used to improve accuracy and repeatabilityAutomation used to decrease cycle times
AUTOMATED CUTTINGAutomation is key to meet cycle times required for high volume automotiveAutomated cutting table will optimise material usage by nesting the blanks as kits and batches
OPPORTUNITIESHigher fibre weight materialOptimisation of the blank shapeCut multiple plies
OPPORTUNITIESOptimise material tackAutomate removal of interleavesOptimisation of speed settingsReduce ply count
Manufacturing at WMGPREFORMING
To achieve complex shape of Prepreg element of the tieblade, preforming was required.This was out of scope of the original project so a tool was designed and manufactured in‐house at WMG at reduced costA manual preforming operation was developed which allowed preforming and cutting of the Prepreg to net shape ready for compression moulding
OPPORTUNITIESUse forming simulation to optimise blank shape for preformUse more complex holding fixture to ensure blank is held and tension maintainedAutomate the process using more capable press
Manufacturing at WMGInstrumentation
6 x Pressure sensors3 x Heat flux sensors2 x Dielectric sensors
Manufacturing at WMGCompression Moulding
Prepreg, Steel and SMC in single process stepPrepreg and SMC from Mitsubishi Rayon Company Limited
Process parameters150°CMoulding pressures up to 100barUnder 5 minutes cycle time
Video of Manufacturing
CAE Correlation
System Rig CAE detailed setup, to gain correlation.
CAE model created to represent as much detail in the test rig as required.
Correlated system rig used within CAE to predict Composite Performance on RIG
Project Aims and ObjectivesCost
Material costs are high for Carbon Fibre CompositesMaterial cost for hybrid composite component is £130
Weight ReductionSteel component weights 6.15kgHybrid component weight of 4.00kgThis results in a target weight reduction of 35%
High Volume Manufacturing
Cycle times under 5 minutes demonstrated for this hybrid compression moulding processPreceding processes showed opportunities with automation would align to 5 minute cycle times.
Engineering RequirementsMet engineering requirementsGood correlation back to CAD models
Follow on WorkEPOCH HVM Catapult project
To continue from the learning on CLASS we have automated the preforming process.Compression moulding of different materials such as Epoxy SMC and NCF Prepreg.
Future Suspension projectsSuspension components come with very challenging load cases, the exploration of these hybrid one step processes is of interest to the CLASS partners.
SimulationDevelop robust SMC flow models for complex shapesGenerate models to simulate the co‐curing of Prepreg and SMC materials Simulate the Prepreg distortion brought about by SMC flow
