engineering passion seite 1 31.03.2017 molding 2017 · combination of injection molding and...
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Engineering Passion
Jason Holbrook – Krauss Maffei Corporation - 2017
31.03.2017Seite 1
One-Shot, Automated Molding of Structural Composite Parts
MOLDING 2017
CellForm (MuCell)Foamed parts
RTM Carbon Fiber with PUR
IMC Injection molding compounder
FiberFormIMM with organo sheets
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Lightweight portfolio covers the entire range of requirements
IMMRPM
FiberForm Injection Molding Compounder
Short glass fiber injection moldingLong Fiber InjectionRTM
Increasing mechanical properties
Increasing cost efficiency
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Fiber Composite materials offer a wide spectrumFiber length vs. Product properties
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Fiber length in the component
mec
hani
cal p
rope
rtie
spa
rt c
osts
Fiber Mat
Fabric
unidirectional
0 10 100 1000 10000 quasi ∞
Com
pone
nts
com
plex
ity
Direct Fiber
Unreinforced Short FiberLong Fiber
Injection molding
Compressionmolding
GMT
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The importance of light weight designCO2 emission are directly linked to the weight of a vehicle
Increase of car weight because of• Convenience• Safety• Quality• Legislation• Interior
Consumption of a car is linked directly to the car weight
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The importance of light weight designReplacement of steel/ aluminum by carbon fiber
Challenges for OEM with fiberapplication• Design of components• Material selection• Production know how• Behavior of metal component• Weight/ Quality/ Cost
optimization• Qualitiy control• Testing• Recycling• Tear 1 - network
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Future of Urban mobility BMW i3
Source. http://www.bmw.com/com/en/insights/corporation/bmwi/concept.html#lifedrive
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FiberForm: Composite sheet integrated into injection molding
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Textile Reinforced parts with functional integrationCombination of injection molding and thermoforming
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Combination of both methods leads to: High strength and stiffness High design freedom High functional integration High degree of automation Short cycle times
Achievable stiffness, strength,Energy absorption capacity
high
low
Com
pone
nts
com
plex
ity
low high
Thermoformingof textiles
Injection molding
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Cost efficient production in an one-stage-processFiberForm – schematic process description
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1
1. Organo sheet intake2. Organo sheet heating3. Transfer into injection mold4. Thermoforming5. Injection molding6. Final part removal
2
3
45
6
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Source: Bond-Laminates GmbH
Composite sheet based on a thermoplastic matrix
Reinforcement is a woven fabric or an unidirectional fabric (UD-Tape)
Local or continuous fiber reinforcement
Various thermoplastic matrix systems (PP, PA, PPS, PEI, PEEK, …)
Different fibrous reinforcements (glass, carbon, aramid or mixed forms)
optimized design for application is possible (fiber orientation, layer structure)
Thermoplastic laminates offer many opportunitiesMaterials and set-up
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Application: – Technology part K2010, similar to side impact
beam (“TAT”) by AUDI – ~ 55 sec cycle time, ~ 590 g weightInnovation:– Transformation to thermoplastic with given
construction space – Process symbiosis of thermoforming and injection molding– Back injection with consolidated composite laminates in
one stepBenefit:– Lightweight parts > -20% compared to steel– Plastic parts with high impact strength– Parts ready for assembly directly after demolding
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Engineering Passion
K2013 – CX 300-1400Hollow body demonstrator
31.03.2017
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FiberForm: Concept for the K-Show 2013
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Hollow profile Local reinforcement
Functional integration
fasteners
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Production cell available for customer trials in MunichCX 300-1400 FiberForm in the technical center at KraussMaffei Munich
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50% weight reduction compared to traditional injection molding!CX 300 – 1400 FiberForm
Application Airbag housing PP/GF30 with PP-organo sheet Cycle time: < 40s
Innovation LRX as TwinZ – Robot Carriages Scales for monitoring the constancy of the
shot weight, integrated in MC6 IR-oven control integrated in MC6 Blending of higlyh concentrated PP/LGF60 Compact production cell (-25% of area)
Partner Takata, Siebenwurst, Bond-Laminates,
Borealis, Motan-Colortronic
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Cycle time reduction through LRX TwinZFurther development of the FiberForm-Automation from NPE USA to Fakuma
Cycle time
FiberFormGeneration
ProductivityPLUS
FiberForm-Cell NPE USA 2015Automation: LRX 150
Cycle time: 45s FiberForm-Cell Fakuma 2015Automation: LRX 350 TwinZ
Cycle time: 40s
Reduction of the cycle time by 5s through decoupling the organo sheet input process and the part removal process
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Reduction of floor space through integration of the automationFurther development of the FiberForm-Automation from NPE USA to Fakuma
Floorspace
FiberFormGeneration
ProductivityPLUS
FiberForm-Cell NPE USA 2015
FiberForm-Cell Fakuma 2015-25% floor space required
Reduction of the floor space required by 25% through integration of the automation in the safety enclosure of the IMM
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Engineering Passion
FiberForm: Molding 2017Prototype for a holder
31.03.2017
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Plastics 4.0 – Intelligent machines through QR-Code-LabellingCX 300-1000 FiberForm
Mold- 1 Cavity- Hot organo sheet is put
onto holding pins
CX 300-1000 FiberForm
Automation- LRX 250 TwinZ
Infrared heating system
Peripherals- Temperature
management device
- QR-Code printer- Organo sheets
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Clamping force 3.000 kN
Screw size 50 mm
Part Prototype for a holder
Material
Organo sheet
PA 6: DURETHAN BKV 55 TPXglass fiber reinforced PA: TEPEX® dynalite102-RG600(2)/47 % black
Part / Shot weight 190 g
Mold 1 Cavity / Company Siebenwurst
Cycle time 39 sec
CX 300-1000 FiberForm: Information about the production cellSemi-structural composite part in less than 40s of cycle time!
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Simplified FiberForm process: the new generation of heating up
Reduced rejectsPreheating program for shortened start-up processes
Uniform heating upSynchronous heating up of the individual heating zones by using a control algorithm developed in-house
Highest component qualityHighly dynamic controller prevents the set temperature from being exceeded
Process transparencyQuality monitoring of the entire heating curve graphically displayed in the MC6
FiberForm – The new generation of heating upCX 300-100 FiberForm: Innovations within the infrared heating system
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FiberForm – The new generation of heating upVisualization: Integration of infrared heating system control in MC6
Monitoring of heating zones
Display of heating curves
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Final part on conveyor belt and QR-Code scan operationPlastics 4.0 with QR-Code
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Multiple kinematics – easily control many axes
LRX 250 TwinZ linear robot with 2 x 25 kg payload
Twin robot with mechanically coupled axes MC6 integration of all axes Incorporate up to 24 axes with one control
system Compact automation integration within the
injection molding machine enclosure
Intelligent automation concept saves cycle timeLinear robot LRX 250 TwinZ
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Application example - Marker binding for tour skiingMARKER Kingpin – Development with the S&W GmbH
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Injection molded edge surrounding – 1mm wide
Organo sheet
Functional integration via 3 hot runners (Needle valve)
Forming
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Part information Production cell: CX 300 - 1400 Injection molding material: PA6 GF30 Organo sheet: PA6 GF Cycle time: < 60s Weight: 325g Approx. 50% savings in weight compared to
steel part
Partners
Application example - Connection of two organo sheetsAudi A6 Infotainment carrier
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KraussMaffei Technologies…FiberForm History…long-term experience with continuous fiber-reinforced FVK
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2004 2006 2008 2010 2012 2014
Frontend with organic sheet in the upper belt
door knot
SpriForm –cross beam
Technology carrier –TAT
A second fully automated production cell is availablefor customer projects!
Airbag housing –Takata
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C-RTM
Surface RTM
HP-RTM
Wet pressing
T-RTM
RTM process familyselection of the technologies according to part design/property
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HP-RTM TechnologyHigh Pressure Impingement and Injection Process
Advantages of the HD-RTM Process:
• Expecially for parts with complex 3D geometries• Fast filling of a closed cavity• Complete impregnation of fiber preform by raised cavity pressure
• Short cure times leading to short cycle times
• Injection from the side
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Compression RTM TechnologyHigh Pressure Impingement and Press Stroke
Advantages of the C-RTM process:
• Especially for 2D parts to avaoid the wash out effect• Fast filling of cavity, cavity not entirely closed (0,3mm)• Fast curing chemical systems• Impregnation of fiber preform with press stroke movement
• Lower press force need without cavity pressure (compared to HP-RTM)• Use of Aluminium tools• Injection from the centre
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Wet-RTM TechnologyHigh Pressure Impingement and Laminar Layer Pour
Advantages of Wetmolding process:
• Processing of fast reacting chemical systems with high pressure impingement
• Use fiber mats made out of recycled fiber pieces
• No cavity pressure – less sophisticated tool design
• No cavity pressure – less press force needed
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Wet-RTM TechnologyReturn of recycled fibres into CFRP parts
RoofUnderbody structure partsRear seat structrure
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Which are typical applications for HP-RTM? Structural parts and carbon designer parts
Side Frame
Roof and Bonet
Underbody structure
Seat structure
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European Automotive industry is already using RTM Structural parts in series production
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Composite surface technologyMotivation of the joint development
Sink marks due to different shrinkage of reinforcement and matrix
In general direct conventional spray-coating is not possible
Sink marks and other surface defects can be covered by In-Mold Coating with ColorForm technology
Post shrinkage must be controlled
Weld lineSink mark
Streak(fibers, humidity)
Pore, pinhole
Class-A surface
>0,3
mm
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Lightweight design & high quality surfaces efficient combination of two megatrends force further developments
2013 Roof element Roding R1 Key characteristicsDimensions 772x585 mm
Total part weight 2.570 g (weight of surface material) (230g)
Substrate thickness 2 mm
Surface layer thickness 0,2 mm
Fiber content (by volume) 50%
Fiber Layup quasiisotrop
Cycle time 6 min
Surface Quality met the specification of German
automotive OEMs
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Summary K-Show ApplicationWorld premier – Surface RTM
World-new two-step RTM infusion and overmolding processHigh quality paintable surface for CFRP automotive exterior partsJoint project among technological leaders of PU and light weight manufacturing companiesCombination of high-performance light weight parts with high quality surface enhancement
www.surface-rtm.com
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Cooperation among company research Team VW, BASF,KMB-Pillar Reinforcement Part
• EA absorption properties –pole crash test
• Replacement high strength steel –weight reduction 36%
• different wall thicknesses applied – 6.3mm to 12mm
• Fiber volume content from 54% to 58%
• injection and curing less than 5min (target less than 3min)
• Recyclability combination with an injection molding process
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Carbon Composite Network Network to Supply “Turn Key Solutions”
LCC
Carbon Composite
Network
ToolingEpoxy Matrix
PU Matrix
Carbon Fibres
Part design Prototyping Design calculation
General Development
Manufacturing
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Engineering Passion
Injection Molding Compounder – IMC
Seite 403/31/2017
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Injection molding: Single screw Material processing Discontinuous process
Extrusion: Twin screw Material compounding Continuous process
Get the benefit togetherInjection Molding Compounder (IMC) – Principle
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Continuous and discontinuous – Two in OneSchematic process description
Shot-Pot-Injectionpiston
Weighing, dosing and conveying systems
CX-, GX- or MX-clamp
Melt buffer
Shut-off nozzle
Start-up valve with container
Twin screw extruder
Re-direction valve
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Less is more... Less cost - more profitMaterial cost savings – Save one stage’s added value
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ATransport
DosingPredrying
PlastificationHomogenisation
DegassingGranulating
CoolingPredryingTransport
SiloWeighingPackaging
TransportSilo
TransportPredryingTransport
Plasticizing
PlastificationHomogenisation
Degassing
BTransport
Dosing
CTransport
Dosing
DTransport
Dosing
ATransport
DosingPredrying
BTransport
Dosing
CTransport
Dosing
DTransport
Dosing
Injectionmolding
Injectionmolding
∆ 0,30 – 1,00$/kg
I
M
C
Compounding
IMM
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Fibers Longer fibers and homogenous dispersionBlends Specialties - Reactive Blends, fiber
reinforcement,...Fillers High fill grades, substitution possibilities
Benefit: Material cost savings – At least 0,30€/kg Almost everything is processable
One for all – Do you know a more flexible system?Highest flexibility – Material choice
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One-heat-process One plasticizing operation less Less shear stress Less thermal stress
Benefit: Higher part quality – particularly with
temperature sensitive materials like PA More homogeneous material and
improved flow behavior
Improved material quality because of reduced thermal stressOne-heat-process – Better material quality
Conventional IMC
Plasticizingat Compounder
Raw material supplier
Plasticizingat manufacturer
Product
needless
Raw material supplier
Plasticizingat manufacturer
Product
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Material responsibility – We assist youContinuous extrusion process – Clear-cut documentation
Throughput
Screw speedextruder
Ongoing cycles
Percentage ofsinglecomponents
Mass temperature
Control of roving
quantity
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The IMC-Technology in operationOverview of current IMC-applications
3/31/2017Seite 47
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
CellForm - Accurate, more lightweightAndreas Handschke, KraussMaffei Technologies GmbHMunich 2015
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
N2, CO2granulate
BasicsCellForm-Technology
Indirect introduction of gas Foaming with opening stroke
TSGChemical foaming
OCM (SGI)Opening Compression Molding
MuCellPhysical foaming
Direct introduction of gas
CellForm
CellForm Advantages
Dimensionalstability
No sink marks/ flashes
Reduction of cycle
time
Less clamping
force
Reduction of material/
weight
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
SCF has the incompressibility of a liquid and the diffusion properties of a gas
Over 90% of all MuCell-applications run with N2
0,2%-2% gas percentage, depending on material
The physical behavior is the advantage...MuCell basics
Compact skin – high density
Foamed core – low density
Integral foam structure, closed-cell Microcellular cell structure: 30 - 100 µm Homogeneous cell formation and –size In general, all thermoplasts can be foamed
MuCell is for stabile parts
MuCell is universally usable
60
gaseous
solid liquid SCF
Temperature [°C]
Pres
sure
[ba
r]
10000
100
1
0,01
0,001-140 0 20-20-100 60
Criticalpoint
Phase diagram
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
MuCell: launched in the millenniumHistorical overview
1969 1998 2007 201220011979
2001: series start-up1979: MIT , Boston: Development phys. foaming
1969: KM-TSG-Mach.
1998: marketing Trexel
2006: visible part cable cover
2007: Large-scale part; door panel
2014
2012:visible housing with pulse cooling
2012: I-panel, MuCell-optimated
2013: high glossy surface, painting, etc
Picture Press release Borealis
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
The core of the machine MuCellTM – Plasticizing unit
Machine nozzle
Pressure release boltMelt pressure sensor
Spraying protection
Wipe- and mixing zone
Standard 3-zone area for plasticizing
Non-return valve
Middle non-return valve
Active back pressure
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
SGI: Opening Compression Molding (OCM)
Advantage High material reductions possible Defined, controlled foaming degree High bending stiffness possible
Machine equipment CellForm-package (chemical or MuCell) Hydraulic for OCM OCM-Software For direct stroke via machine movement
– compression molding package + parallelism control (+ parting line control)
1) 2)
Non-complete volumetric filling
Foaming untilcavity is full
complete volumetric filling Foaming starts with opening
Standard foaming:
OCM:
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
If weight and dimensional stability is decisiveMuCellTM - Application
Door panels Valve hood
Door lock cover
Carrier part for printer
Side coverWater pump housing
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
Versatile possibilities MuCell® - Applications in the Automotive industry
Filter housing
Visible parts
2K-motor cover
Instrument panel
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
Higher invest, less costsSaving per year
Rise of productivity: 18% – Cycle time reduction
45s 37s = 8s– 480.000 parts 583.000parts 100.000 parts more
Higher Investment: +82.700 € – AX230 AX130 - 73.800€ – MuCell-Investment: + 100.000 € – DMH: + 56.500 €
Energiecosts +20.700 € Material saving -95.500 €
– 35% = 59g– 59g x 583.000parts = 34.397kg– Foaming agent 0,5% 540€
ROI of production system: 1,1 years
3 mm
1,8 mm
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
Over 130 MuCell-machines
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Chemical Foaming MuCell Other Foaming Technolog. Additional Process Contact Basics SGI
THANK YOU FOR YOUR TIME
Jason HolbrookSales ManagerKrauss Maffei Corp.
Tel.#: 859-653-4309Email: [email protected]
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