High Volume Automotive Applications Addressed by the ...images.jeccomposites.com/jw17/presentations/5.Braiding-Taking-the... · DC0 Öffentlich - (erberan) High Volume Automotive

DC0 Öffentlich - (erberan)

High Volume Automotive Applications Addressed by the Braiding Technology

JEC World Conference 2017

Dr. Andreas Erber | Paris | March, 2017

Page 2 | JEC World Conference 2017 DC0 Öffentlich - (erberan)

Markets

Acrylic Fibers

Automotive

Aerospace & Defense

Wind

Industrial

Business Unit Composites – Fibers and MaterialsOur solutions serve key markets

Unique integrated value chain

Fibers

Materials

Engineered Solutions

Broad portfolio of high-performance products - Acrylic Fibers - Stretch Broken Yarn- Oxidized Fibers - Chopped & Milled Fibers- Carbon Fibers

Production technologies along the fiber value chain - Woven Fabrics - Preforms- Non crimp Fabrics (NCF) - Prepregs & TowPregs- Nonwovens - Tapes & Organo Sheets- Braidings - Wet Friction Materials

Lightweight and Application Center (LAC) In-house bridge between SGL products and customer applications in the development of fiber reinforced composite components - Engineering solutions and manufacturing prototypes (e.g. CFRP Parts)


Business Unit Composites – Fibers and Materials Production network covers the whole value chain

Precursor and acrylic fibersCarbon fibersMaterialsComposites

RiedOrt

Gardena Arkadelphia


New electric vehicle concepts with pioneering design

Carbon fiber in automotive series productionBMW i - Born Electric

Source: BMW Group

BMW i3/i8

Series

BMW i3.

BMW i8.

▪ Overall concepts dedicated to battery electric mobility

▪ Structural design aligned with composite requirements

▪ Large scale production of carbon fibers and composites


CFRP supply chain

SGL Group’s composites in the automotive industry Lightweight expertise for the BMW Group

Source: BMW Group

BMW i3/i8

Series

Precursor Carbon Fiber Production

Textiles and Recycling

Composite Components

BMW i3/ i8 Production

- Japan - - USA - - Germany - - Germany - - Germany -

1 2 3 4 5

2 | Moses Lake

3 | Wackersdorf4 | Landshut

5 | Leipzig

Mitsubishi Rayon-SGL Precursor SGL Group BMW Group

1 | Otake


SGL Group’s textile material toolboxbased on carbon and glass fibers

Tailored Textiles▪ UD textile▪ Local reinforcement

Fabrics▪ Various textile

architectures▪ Laminar

reinforcement

Nonwoven material▪ Random orientation▪ Based on secondary

fibers and textiles

Preforms▪ Comprising

different textiles▪ Local reinforced

Textiles▪ Carbon and Glass fibers based▪ Various semi-finished materials

as a toolbox approach▪ Bindered textiles for preforming


Braiding technologyEveryday Life

Principle of hand braiding

Braided bakery product

Source: TU Munich


Braiding technologyMachine principle - history

Braiding „machine“ from Japan784 - 1185 n.Chr.

• 15th March 1748first reference of machine braiding

• 1780first operational braiding machine

• 1898significant advancement of the horn gear arrangement

Source: TU Munich


Transmission shafts by braiding technologyExample: Commercial aircraft high lift system

Radial braiding machine (64 carrier)

Biaxial fiber architecture

Triaxial fiber architecture

Differential design:Braided transmission shaft with metallic flanges

High lift system of a commercial aircraft

Source: University Stuttgart

Source: Liebherr Aerospace Lindenberg GmbH

Source: University Stuttgart


Integral design of transmission shaftsComposite flanges

Integral versusdifferential design

Flanges offer a huge lightweight potential

F

F

Principle of flange manufacturing tool Braiding of flange; step #1 Braiding of flange; step #2Source: PhD Thesis A. Erber


Integral design of transmission shafts Composite flanges

Challengebearing stress

Non-reinforced flange; 3 x M6

0

100

200

300

400

500

Ve

rsa

ge

ns

las

t [N

m]

200

220

240

260

280

300

Ge

wic

ht

[g]

Versagenslast

Gewicht

Unverstärkt Spiralverstärkung Radialverstärkung

3 x M8

Wei

ght [

g]

Failu

re lo

ad [N

m]

Failure load Weight

Non-reinforced Spiral reinforcement Radial reinforcement

Spiral reinforcement Radial reinforcement Source: PhD Thesis A. Erber


Industrialized braiding technologyBMW 7 series side roof frame

Significant weight-savings through lightweight chassis

Source: BMW Group

New BMW

7 Series


Industrialized braiding technology BMW 7 series side roof frame

• Braided side roof frame as reinforcement of a steel sheet

• Overbraiding of a thermoplastic core• RTM process (thermoset matrix)

Industrialization of a hybrid component within a multi-material body in white design.

Source BMW Group


Serial production at SGL KümpersBraiding of the side roof frame preforms

Source: SGL Kümpers GmbH


Lightweight and Application Center (LAC)Understanding customer needs

▪ Application of SGL products in customer processes

▪ Characterization of SGL materials for design and process engineering of customer applications

▪ Design and simulation for composite parts

▪ Demonstration of automation and serial production capability

▪ Prototyping and low volume production according customer requirements

Concept development

Design and simulation

Prototyping and testing


Example: Braided transmission shaft

Lightweight and Application Center (LAC)Understanding customer needs

• Design tools (CAD)

• Laminate design (FEA)

• Process simulation

• Digital manufacturing

Material and preform simulation

Process simulation

▪ Material cards for customer simulation▪ Material characterization with respect to processing▪ Design of structural components, modules and tools▪ Weight and cost engineering of components

System simulation

Design and optimization

Source: PhD Thesis A. Erber


Lightweight and Application Center Understanding customer needs• Thermoplastic pultrusion• Filament winding• Robot based winding• Wet pressing• Thermoforming• Pick & Place Technologies

Virtual reality: Robotic cell as an example Process Technology


Business Unit Composites – Fibers and Materials

Source: BMW Group

We are taking lightweight design to the next level – together with our automotive customers.

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High Volume Automotive Applications Addressed by the ...images.jeccomposites.com/jw17/presentations/5.Braiding-Taking-the... · DC0 Öffentlich - (erberan) High Volume Automotive