norwegian aluminum competence is of strategic importance
TRANSCRIPT
Norwegian aluminum competence
is of strategic importance to Benteler Automotive
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NTNU Nettverkskonferanse 27. april 2016
S.-T. Strandlie
Benteler Automotive Raufoss
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Confidential / Draft
© BENTELER International AG | Page 3
CMS Front –G30/31
BMW 5 Series
SOP 05/2016; 230,000 veh/yr
Beams: BAT Raufoss
Crashboxes: BAT Skultuna
Assy/Welding: BAT Jablonec
Plant Raufoss
New Projects – Aluminium Systems
Confidential / Draft
© BENTELER International AG | Page 4
CMS Front/Rear, LLP and Crossmember – SPA V54X, L541
Volvo S90/V90
SOP 04/2016
V54X 88,734 veh/yr
L541 52,628 veh/yr
Beam: BAT Raufoss
Crashboxes: BAT Raufoss
Assy/Welding: BAT Raufoss / BAT Skultuna
Cross member: BAT Raufoss BAT Jablonec (relocation)
Plant Raufoss
New Projects – Aluminium Systems
Front Crashbox
Front Beam
Rear Beam
Lower Load Path
Crossmember
There are currently some 1700
different extruders in the world Source: Aluminium Times
This is a large supplier base, but
with a big scatter in performance,
quality, cost, footprint, technology
etc.
Market is growing – Technology edge needed
Future Growth of Aluminium Extrusions in Automotive -
Body and Bumper
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Source: Ducker Worldwide; Light Vehicle Metals Market Analysis
and Forecast June 12, 2012
The OEM’s starting to:
- Categorize material classes
- Define more strict standards
- Define suppliers for each class
- Meet best price globally
02/2014 I A. Artelius I Version 3
40.000 T in
2013
170.000 T in
2025
Market Driven Technology and Innovation Development
0
10
20
30
40
50
60
70
80
90
1970 1975 1980 1985 1990 1995 2000 2005 2010
WW
au
tom
oti
ve
pro
du
cti
on
Mill
ioner
yearMain sources: WMVD, SMMT, JAMA, IRF, CCFA, OICA.
Elaboration Freyssenet M., 2004 and updatings.
RollformingStretch bending and
solutionizingCross-section reforming
2-cavity
3D-bending
3-cavity
Hybrid die’s
Automation
Digital controls
U-profiles Stiff beams Hollow and flexible1-piece
Crash boxes
Welded
System
high strength alloy’s adaptedfor extrusion
Higher productivityImproved corrosion resistance
Ultra high strength
Product
Process
Material
Necessity of Continuous Technology and Innovation Development
- material, process and products
How can we stay in technology lead?
+
Manufacturing
value chain
Casting Extrusion Forming Finishing
Engineering
value
chain
Alloy and heat
treatment
Extrusion
process
Forming
process
Tool
design
Product
design
Prototyping and
Product verification
Integrated Optimization – Product, Process and Material
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Pro
toty
pes
To
olin
g
Historical technology development
- customers, material, process and products
Success driven by market driven technology development
1970 1980 1990 20102000CMVSS AZT RCARFMVSS
MonobeamOpen stiff Open flexible
CB bolted
CB weldedClosed flexible
Closed stiffStick-in
Rollforming Stretch bending
and solutionizingCross-section
reforming2-cavity
3D-bend
Hybrid die’s 3-cavity
2D-ben
7030 (~360MPa)
7108 (~360MPa) 7021 (~480MPa)
Open
7108(~320MPa)
Closed7003 (~380MPa)
Corrosion
7046opt (~500MPa)
Extr optimized
7046 (~440MPa)
Closed
7108(~420MPa)
Closed
8A. Artelius / 01.07.2013
R&D and Innovation activities needs link to Centers of
Competence – Material, Process and Products
SimLAB - methods and tools for the virtual product development
NorMan - advanced manufacturing technology
AutoPart – spare parts manufacturing
AlFEB – Alloy development
AutoFlex – Tool change-over
Tax funding (typical funding: 250 kEUR/year)
2010 2011 2012 2013 2014 2015
AluCaW – Hybrid cast-extrusion
TIP – Traceability
2016
NextForm – additive manuf.
Lean Operations
User Controlled Innovation Project: industry in-kind 70%, R&D funding: 30% typical 3 yrs, ~ 3 MEUR To stimulate R&D activity in trade and industry, particularly activities that promote innovation and sustainable value creation.
Centre for Research Based Innovation: industry funding 25%, typcial 7 yrs, 30 MEUREnhance the capability of the business sector to innovate by focusing on long-term research based on forcing close alliances
between research-intensive enterprises and prominent research groups.
Knowledge-building Project for Industry: industry funding 20%, typcial 3 yrs, 3 MEURIndustry-oriented researcher training and long-term competence development in the community within topics that are crucial
to the development of business and industry.
SMART – Multi-material process and products
CASA – advanced structural analysis
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Research and Advanced Development a necessity for long-term
competitiveness
Markedet er representert ved løpende kontakt gjennom industrien, dette er den viktigste
drivkreft for langsiktig Forskning og fremtidig Kompetansebehov.
Innovasjonen kommer til uttrykk gjennom smarte produkter og produksjonsprosser som må
utvikles paralellt.
Kortere ledetid fra ide til industiell implementering er et vesentlig konurransefortrinn for
Skandinavisk industri, dette kan foredles videre.
Et cluster med NTNU, Sintef og Internasjonale industribedrifter som kan dele /samarbeide på
felles problemstillinger og muligheter ved å skape en arena hvor studenter slipper inn i
fellesmiljø hvor forskning, pilotering og prototypproduksjon kan være en strategisk visjon med
potensiale i seg!!
Ny Teknologi - Innovative produkter/processer - Utvikle Talenter
Industriens drivkraft for samarbeid med NTNU
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