alseca group new part concept cycle - catia | … · alseca group new part concept cycle ... • 3d...
TRANSCRIPT
INNOVATION EMPOWERED
ALSECA Group
New Part Concept Cycle
Our objective is to create added value, based on world class engineering know-how, highest innovative spirit and environmental care.
We want to accomplish our mission by delivering creative solutions that provide sustainability.
We also want to be able to establish an empowering working environment that promotes talent and maximizes employees potential.
STEP 1: • PRELIMINARY PROPOSAL
DEVELOPMENT
– Solution study – Concept definition
1. Preliminary Work
• Market / solution study
• Concept definition
• Engineering estimates
General Requirements for Wheel Liners
• • • • • •
• •
• • •
• • • •
Simple Injection Molding Design
• • •
• • •
•
•
+ One step mfg. process + Shape freedom to
accomplish functionality
- Poor impact resistance - Poor soundproofing performance - Overall part is still heavy (technology related
limitation)
Injection Molded Reference
•
• •
Inj. Molding Design w/ Soundproofing Pad
• •
• • • •
•
•
+ Simple 2 step mfg. process
+ Shape freedom to accomplish functionality
- Poor impact resistance - Improved soundproofing performance
comes with price penalty - Overall part is still heavy (technology related
limitation)
Non-woven Thermoformed
• •
• • •
•
•
•
+ Lowest part weight + High sound proofing
performance - High piece price cost - Low impact resistance
Thermoformed Reference
•
•
• •
Top view
Side View
Vacuum Formed
• •
• •
• • • •
+ Lower part weight + Low tooling investment
- High piece price cost - Part shape and design limitations - Improved soundproofing requires padding
Vacuum Formed Reference
• •
• •
•
Top view
Side View
Welding area (4 points)
Insulating NVH-Pad
Hybrid Design
• • • • • •
• • •
•
+ Lower part weight + High performance (NVH,
rigidity) + Best value for landed cost
- Development & validation challenges
Hybrid Design Reference
•
•
Side View
Front View
Insulating NVH Inserts
Plastic Frame
Alseca Hybrid_1 Proposal
Alseca Hybrid_2 Proposal
Conclusions
• Alseca is capable to deliver multiple design options • Some of the requested definitions may raise challenges
– Non-woven design usually requires additional attachment points – Vacuum forming has limitations for geometrical definition of the part
• Alseca hybrid design proposes two options: – A three piece inserts for reduced part weight and improved NVH
performance – A one piece insert that is lower cost – The option of a single material part (PP) provides 100% complete
recyclability
• Both hybrid as well as injection molded options pertain to Mucell-assist processes that provide:
– Reduced part weight – Improved part rigidity; better dimensional stability – Reduced manufacturing cycle
STEP 2: • DETAILED DESIGN PROPOSAL
DEVELOPMENT
– 3D Scanning – Reverse Engineering
2. Detailed Solution Development
• Existing part sample 3D scanning
• Reverse Engineering reconstruction
• Implement new product requirements in 3D data
• Development of a feasible, manufacture-able design
Project Steps & Milestones
3D Scanning
• Optical scanner: GOM Atos III hardware • 8 million megapixels
• Scanning time (including part preparation): ~5 hours
Digitized Mesh Shape Editor
Quick Surface Reconstruction
Mesh Checking & Repair
Surface Accuracy Analysis - Automatic
Surface Accuracy Analysis - Manual
Surface Construction References
Generative Shape Design Catia V5.R21
Concept Comparison Part Layout and Concept Comparison
Part Configuration Comparison Part Layout and Concept Comparison
Tool Layout & Concept Summary and Conclusions
Conclusions
• High-quality & fast turn around is expected for engineers
• 3D Scanning & Reverse engineering provide a solid, validated infrastructure
• Catia V5 has world-class tools available for advanced product design