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© 2017 by Plasan 1 Plasan proprietary information
HYBRID COMPOSITE DOOR BEAM FOR MASS PRODUCTION Design, Analysis, Optimisation, Testing, Productionisation
© 2017 by Plasan 2 Plasan proprietary information
ABOUT MYSELF
Coventry University Transport Design Graduate
Chief Designer of Plasan since 2001
Director of Design since 2013
NIR KAHN
© 2017 by Plasan 3 Plasan proprietary information
CONTENTS
About Plasan
Predicting composite behaviour in crash
Design architecture for mass production in composites
Complying with requirements written for metals
Door beam case study
Summary & Questions
20 minute “crash course”
© 2017 by Plasan 4 Plasan proprietary information
World’s leading designer and supplier of lightweight composite vehicle bodies
ABOUT PLASAN
>1000 composite vehicle bodies/month
© 2017 by Plasan 5 Plasan proprietary information
ABOUT PLASAN
International company with R&D and manufacturing facilities in Israel, US, and France plus broader partner network
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ABOUT PLASAN CARBON COMPOSITES
World’s leading supplier of Class A carbon-fibre automotive parts
SRT Viper bonnet photo: SPE Automotive
CLASS A 40K CARS
PER YEAR
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LEADING THE INDUSTRY
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Paradigm shift for the automotive industry
40K CARS PER YEAR
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MASS PRODUCTION FACILITIES
Grand Rapids, Michigan, USA Dedicated to mass producing composites for the automotive industry
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HIGH RATE DYNAMIC ANALYSIS AND TESTING THE MODEL BLAST TEST
• A mine blast is essentially the same as a crash impact, just from underneath
• Hybrid III dummies • Simulation calibrated by physical testing
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CARBON COMPOSITES CRASH MODELING
Force
[kN]
Displacement [1E-3m]
Velocity [m/s]
Steady state forces -20000 N
Braking Forces -120000 N
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“when you combine it with Plasan’s ideas for the use of materials … and general production ethos, it will be vehicles like the Plasan SandCat that really revolutionise the car industry”
“it’s all essentially about absorbing and redirecting energy, about making a strong, safe, effective vehicle. It’s an extreme version of what every car manufacturer on the planet is trying to do”
TOM FORD
TOP GEAR MAGAZINE JULY 2016
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TRANSFERRING KNOW-HOW & TECHNOLOGY
• Applying principles that successfully moved military vehicles from welded bodies to multi-material architecture
• Strength, safety, weight, and cost driven
• Efficient use of the more expensive materials Performance
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• Cost per kg saved is lower the harder the part is working
• Design architecture to concentrate loads in these areas
• Design parts for production with processes that are cost effective for composites
COST/KG SAVED
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THE FIRST PROPOSAL TO MAKE CARS FROM PRESSED STEEL
How can we get steel to splinter on impact like the
regulations require?
But welds are ugly and how will we give it that beautiful wood texture
that our customers expect?
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DESIGNING A MASS-PRODUCEABLE COST-EFFECTIVE COMPOSITE BIW
Pultrusions Metal
composites
RTM
Pressure Press
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ROOF CRUSH FMVSS 216
Local buckling: F = 8 [ton] @ 40mm Global buckling: F = 9 [ton] @ 60mm
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SIDE POLE IMPACT
The frame absorbed the crash energy without penetration into the occupants volume
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STRUCTURAL COMPOSITE CHALLENGES
Meeting standards written for metals
Cracking
Separation
Durability
Fatigue
Paint
Temperature
Attachment
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…BEAMS FIRST
Holistic approach to composites is favourable
To ease adoption of new pultrusion-based architectures Plasan is taking a “Beams first” approach with OEMs
Bolt-on but structural, crash critical
Prove design/analysis/test
Prove produceability, processes, compatibility
Challenging economic challenge to replace a cheap steel stamping
Having made a case for this, the door is open to full BIW
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CASE STUDY – DOOR BEAM
Steel door beam = 1.5kg
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MODEL SET-UP FMVSS 214S
Supports
Impactor (movement 457mm)
Composite or steel beam
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THREE-POINT BENDING DROP TEST
Pure Carbon Fibre, standard lay-up, pultruded beam
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THREE-POINT BENDING DROP TEST
Hybrid Composite, optimised lay-up, pultruded beam
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FATIGUE TESTING
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STEEL DOOR BEAM RESULTS Results of simulations
Maximum force – 16700N
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COMPOSITE TYPE 1 DOOR BEAM RESULTS Results of simulations
Maximum force – 30,000N
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COMPOSITE TYPE 2 DOOR BEAM RESULTS Results of simulations
Maximum force – 25,000N
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DOOR BEAMS FORCE COMPARISON
Results of Simulation
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DOOR BEAMS ENERGY COMPARISON
Results of Simulation
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DOOR BEAM – RESULTS SUMMARY
Design Material Mass, kg Energy, J Peak Force, kN
150mm
Original Steel 1.5 1700 16,700
Composite 1 A 0.85 1800 30,000
Composite 2 B 1.05 2500 25,000
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COMPOSITE (DOOR BEAM) SUMMARY
The main energy absorption mechanism in carbon fibre composites is based on brittle failure
More extensive failure results in more effective energy absorption
Hybrid composite beams allow maximum energy absorption without detachment
Composite beams have better performance than steel beams
Composite beams can reduce weight by 35-40 % cost-effectively
© 2017 by Plasan 32 Plasan proprietary information
לחץ כדי לערוך סגנון כותרת של תבנית בסיס
SUMMARY
Composites can efficiently absorb energy
Heavier and stressed parts have greater
potential
Design for composites
Design for manufacture
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THANK YOU
