HANNOVER MESSE Materials Forumfiles.messe.de/abstracts/52083_101130_Matheis_FG_Kraftfahrwesen.pdf · #103130 · 13su0025.pptx Slide Nr. 1 10.04.2013 © ika 2013 · All rights reserved

© ika 2013 · All rights reserved 10.04.2013 Slide Nr. 1 #103130 · 13su0025.pptx

Novel Fibre Reinforced Polymers for the Automobile Interior

Lightweight Structural Components in a Multi-Material Design

HANNOVER MESSE

Materials Forum

Hannover, 10th April 2013

R. Matheis, T. Schulte, L. Eckstein

Institut für Kraftfahrzeuge - RWTH Aachen University

A. Köver

Johnson Controls Automotive Seating


Agenda

Motivation

The CAMISMA Project

Development and Production of Novel Fibre Tapes

Design of a Multi-Material Structure

Manufacturing of a Demonstrator Component

Summary and Outlook


Motivation

CFRP in Automotive Applications

Diminishing reserve of fossil fuels

Increasing legislative environmental

constraints

Electric vehicle: Optimising range

(compensate weight of battery)

Reduce mileage independent of

powertrain by lightweight design

Current Situation

Steels CFRP

Need for Research

CO2-Emission Legislation in the EU

Pot. Weight red.: Limited Highest

Maturity Level: High Low

Material Cost: Low Very high

Reduction of material and manufacturing cost of CFRP components

Lower cycle time for potential series production

Integration of steel inlays into fibre components for structure connection

Development of a component showing feasibility of the material concept

CO

2 e

mis

sio

ns

[g/k

m]

40

80

120

160

200

240

2000 20202015201020051995

140 g/km

(2008)

185 g/km

(1995)177 g/km

(2000)

95 g/km

(2020)

0

130 g/km

(2015)

Actual CO2 fleet emissions in the EU

European Union legislative emission regulations


Agenda

Motivation

The CAMISMA Project




Summary and Outlook


The CAMISMA Project

Project Overview

CAMISMA – carbon fibre amid metallic structural interior

component using a multi material approach

Funded by the German Federal Ministry of Education and

Research (BMBF)

Project duration: 01.04.2011 to 31.03.2014

Development of innovative and competitive fibre compo-

sites for vehicle lightweight structures

Reduction of CO2-emissions during the production of

CFRP by using fibre manufacturing by-products

Cost-competitive manufacturing of fibre composite

components (low cycle times and production cost)

Boundary Conditions

Targets


The CAMISMA Project

Work Packages

Recycling and pro-

cessing of carbon

fibre side products

Design of a multi

material structure

Manufacturing and

functional

improvement

Economic and

environmental

analysis

Production of

preforms

Production of

laminated tapes

Continuous tape

production

In-situ polymerisa-

tion

Identification of ma-

terial properties

Development of a

backrest structure

FEM analysis

Combination of in-

jection moulding and

thermoforming

Validation of process

on demonstrators

Cost analysis of the

lightweight concept

Life cycle assess-

ment

Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco²


Agenda

Motivation

The CAMISMA Project




Summary and Outlook


Development and Production of

Novel Fibre Tapes

Carbon fibre cuttings of different

lengths are

homogenised by cutting

compacted to mats of non woven

fabrics by aerodynamic formation

Filament spreading of unidirectional

(UD) rovings

Continuous impregnation of pre-

forms (UD fibres and non woven

fabrics)

In-situ polymerisation with

thermoplastic Polyamide 12 matrix

Increased adhesion of matrix to

fibres

Low cycle time

Enhanced economic viability

Production of pre-forms Production of laminated tapes

Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco²


Agenda

Motivation

The CAMISMA Project




Summary and Outlook


Targets:

Development of an automobile seat

backrest structure

Combination of non woven and UD CFRP

tapes with injection moulded GFRP,

directly integrating a steel inlay

Weight reduction of 40 %

compared to a reference

Feasibility and economic via-

bility of production progress

Fulfilling passive safety require-

ments (front/rear impact)

Design of a Multi Material Structure

Development Progress

Static

Analysis

Dynamic

Load Cases

Production

Process

+45 -45 Element Density Dicke [mm]

Targets Extensive Use of FEM

Identification of material para-

meters and validation of appro-

priate material models

0

0

Simulation of rear and front im-

pact (static/dynamic)

Optimisation of GFRP topology

and tape layers


GFRP Injection Mould

Multi-Material Demonstrator

Design of a Multi Material Structure

Multi Material Design

Image Sources: Science-to-Business Center Eco², ITA RWTH Aachen University, HBW-Gubesch Thermoforming GmbH

Reinforcement Rips

Non Woven Fabric Tapes

Back Panel

UD Fabric Tapes

Local Reinforcement

Steel

Recliner Connection


Agenda

Motivation

The CAMISMA Project




Summary and Outlook


Manufacturing of a Demonstrator

Component

Manufacturing Process Proof of Feasibility

Organic

Sheet

Heating

heated

Organic Sheet

SpriForm Tool Forming Process

Injection MouldingMaterial

For Function Integration

Standard Injection

Moulding Machine

Image Source: HBW-Gubesch Thermoforming GmbH

Spri-Form Process

Injection moulding and

thermoforming as one

process step

Steel inlay integrated by

overmoulding

Proof of concept by producing a

sample component

Manufacturing a cut-out of

the final demonstrator

(Currently in preparation)

Manufacturing of the full

back rest demonstrator


Agenda

Motivation

The CAMISMA Project




Summary and Outlook


Summary and Outlook

Filament spreading of unidirectional (UD) rovings

Production of non woven fabric tapes using fibre cuttings

In-situ polymerisation with thermo-plastic Polyamide 12 matrix

Material tests depicted feasibility and good structural properties of novel composites

Successfully integrated novel fibre products in virtual development process

Virtual design of an automobile backrest

Fulfilling safety requirements

Weight reduction of 40 %

Economic manufacturing

Proof of feasibility of spri-form process

Summary Outlook

Implementation of continuous im-pregnation machine

Production of backrest cut-out

Production of full demonstrator

Validation of the requirements

Special focus on crash tests

Cost analysis

Life cycle assessment


Thank you for your attention!


Forschungsgesellschaft

Kraftfahrwesen mbH Aachen

Steinbachstraße 7

52074 Aachen

Germany

Email

Internet www.fka.de

Contact

Johnson Controls Automotive Seating

Industriestraße 20-30

51399 Burscheid

Germany

Email

Internet www.jci.com

Dipl.-Ing. Ralf Matheis Dipl.-Ing. Axel Köver

[email protected]

[email protected]

Documents

HANNOVER MESSE Materials Forumfiles.messe.de/abstracts/52083_101130_Matheis_FG_Kraftfahrwesen.pdf · #103130 · 13su0025.pptx Slide Nr. 1 10.04.2013 © ika 2013 · All rights reserved