composite brake pedal joined by electromagnetic pulse technology
TRANSCRIPT
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Optimization of joining processes for new automotive metal-composite hybrid parts
Grant Agreement Nr: 609039 Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)
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HYBRID BRAKE PEDAL
FINAL EVENT
Ghent, 24/02/2016
Martinho Soares
Toolpresse
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Company in the automotive
industry, specialized in
cold metal stamping,
welding and machining. Factories in Portugal and
Morocco.
Company with extensive
experience in design,
manufacture and testing of
cutting and stamping tools; manufacturing, assembly and
testing of special devices.
Company in the industrial sector
with over 20 years of
experience, dedicated to the manufacture of
parts and metallic
precision assemblies.
HYBRID BRAKE PEDAL
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PRODUCTION PROCESS
STAMPING WIRE WELDING
HYBRID BRAKE PEDAL
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Brake pedal
Brake and clutch pedal
CORE PRODUCTS
HYBRID BRAKE PEDAL
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BRAKE PEDAL An assembly of generally steels components system, which moves a piston in the master cylinder; brake fluid then applies great force to the brake pads or shoes.
HYBRID BRAKE PEDAL
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PEDALS EVOLUTION
Clutch Pedal
Component: Yoke Material: Steel
Component: Body Pedal Material: Steel
Component: Body Pedal Material: Composite
Component: Yoke Material: Composite
OLD PEDAL ACTUAL PEDAL
HYBRID BRAKE PEDAL
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Brake Pedal
Component: Yoke Material: Steel
Component: Body Pedal Material: Steel
Component: Body Pedal Material: Steel
Component: Yoke Material: Composite
OLD PEDAL ACTUAL PEDAL
PEDALS EVOLUTION
HYBRID BRAKE PEDAL
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BRAKE PEDAL
Why current brake pedals are not made of composite?
The elastic and plastic deformation of the body pedal component when subjected to efforts (bending and traction) defined in the requirements, does not comply with the specified values.
Almost all the requirements that the pedals have to meet are related to maximum admissible deformation when subjected to various efforts.
HYBRID BRAKE PEDAL
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TOOLPRESSE PROPOSAL
Develop a new process of making brake pedals that combines composite materials and metal joined by EMJ, in order to provide a consistent alternative to the current state of knowledge of realization of these components.
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MAIN OBJECTIVES Reduce the risk of serious lower limb injuries the driver in a frontal collision The use of composite materials in the production of this components allows to define a non-aggressive geometry, without sharp edges, which greatly reduces the risk of serious injury in case of frontal collision and simultaneously ensuring compliance with legal requirements and international statutory. Reduce the weight of the brake pedal assembly Due to the low specific weight of composite materials, the final weight of the component is less than the weight of existing components made entirely of metal Reduce the cost and the time of the production process Due to the smaller number of operations and components it’s possible to reduce the cost and production time
HYBRID BRAKE PEDAL
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DESIGN STRATEGY
How to achieve the objectives set for the deformation?
HYBRID BRAKE PEDAL
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DESIGN STRATEGY
0,03mm elastic deformation allowed
PA 6.6 GF30 Retangular sample 50x20x300
100Kg
100Kg
2,24 mm elastic deformation allowed
PA 6.6 GF30 Retangular sample 50x20x100
If we consider a part with the length similar of length of a pedal, completely done in composite.
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DESIGN STRATEGY How to achieve the objectives set for the maximum deformation?
If we divide the component in some parts and unit them, the sum of the each individual deformation is less than the deformation of the component with the equivalent length of the sum of the parts.
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DESIGN STRATEGY So the design strategy is divide the body pedal in three parts and join them.
Composite Pad Component
Aluminum Component
Composite Hub Component
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PRODUT DEVELLOPMENT In partnership with the consortium members, the process was developed to ensure the join of the components using EMJ. Test series Description Aim
Preliminiary
Experiment
Samples
1
Connection of an aluminium rectangular tube with a rectangular composite part through a single groove at each side.
• To verify the feasibility to join rectangular shapes with the process EMF
• To verify the absence of cracks.
2
Connection of an aluminium rectangular tube with two rectangular composite parts through a single groove at each end.
• To Verify compliance with the requirements
3 Connection of an aluminium rectangular tube with two rectangular composite parts through a circumferential groove.
• To verify compliance with the requirements
Final
Brake pedal components
4 Connection of a metal rectangular tube with composite brake pedal components.
• To verify compliance with the requirements
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PRODUT DEVELLOPMENT Test series 1: Connection
of an aluminium rectangular tube with a rectangular composite part through a single groove at each side
Composite part: – Material: PA6.6 GF30 – 4 geometrical different
versions
Metal rectangular tube: – Aluminium 6082 – Thickness : 1,50 mm
HYBRID BRAKE PEDAL
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PRODUT DEVELLOPMENT
Test series 1: Connection of an aluminium rectangular tube with a rectangular composite part through a single groove at each side
The connection of a metallic rectangular tube with a rectangular composite part is feasible.
No cracks were identified.
Results
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PRODUT DEVELLOPMENT Test series 2: Connection of an
aluminium rectangular tube with two rectangular composite parts through a single groove at each end.
Based on test series 1:
Test method: Bending test at test bench.
Composite part: – Material: PA6.6 GF30
Metal rectangular tube: – Aluminium 6082 – Thickness : 1,50 mm
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PRODUT DEVELLOPMENT Test series 2: Connection of an
aluminium rectangular tube with two rectangular composite parts through a single groove at each end.
Based on test series 1:
Test method: Bending test at test bench
Composite part: – Material: PA6.6 GF30
Metal rectangular tube: – Aluminium 6082 – Thickness : 1,50 mm
HYBRID BRAKE PEDAL
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PRODUT DEVELLOPMENT Test series 2: Connection of
an aluminium rectangular tube with two rectangular composite parts through a single groove at each end.
HYBRID BRAKE PEDAL
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PRODUT DEVELLOPMENT Sample test vrs 3: Connection of an
aluminium rectangular tube with two rectangular composite parts through a circumferential groove.
Test method: Bending test at test bench
Composite material : – PA6.6 GF30
Metal rectangular tube: – Aluminium 6082 – Thickness : 1,50 mm
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PRODUT DEVELLOPMENT In the serial samples tests we achieve the product specification to complies with the deformation
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Two Grooves Groove all around
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PRODUT DEVELLOPMENT Product design
Pad component
Hybrid brake pedal
Hub component
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PRODUT DEVELLOPMENT Product design
Pad component
Hybrid brake pedal Hub component
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PROCESS DESIGN
Actual Process
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PROCESS DESIGN
Proposal Process
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MAIN RESULTS Reduce the risk of serious lower limb injuries the driver in a frontal
collision. The hybrid brake pedal don’t have a sharp hedges. Reduce the weight of the brake pedal assembly Actually we reduce about 17% of weight, and it’s possible reduce up to 40% Reduce the cost and the time of the production process The proposal production process reduces two operations
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NEXT STEPS
Proceed with the stress tests.
Start the fatigue tests.
Divulgation and presentation the product at fairs.
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Optimization of joining processes for new automotive metal-composite hybrid parts
Grant Agreement Nr: 609039 Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)
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Thanks for your attention