optimizing multi-material parts ... - jec...
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15 March 2017 JEC WORLD
Conference 4 - Current Trends in the Automotive Industry
Optimizing multi-material parts performances thanks tonew metal / thermoplastic composite joining technology.
Contribution in the H2020 COMMUNION project
Not so big weight gain for composite materials as expected
Absence of Value with Advanced Materials
• Expensive manufacturing processes to achieve higher than needed quality
• Overdesign due to sizing– Huge safety margins because of uncertainties due to
manufacturing effects
• Expensive material costs
JEC WORLD March 2017 “Current Trends in the Automotive Industry”
Paris, 15th March 2017
JEC WORLD
Conference 4 - Current Trends in the Automotive Industry
ComMUnion: Optimizing multi-material parts performances thanks
to new metal / thermoplastic composite joining technology
H2020-FoF12-2015
JEC WORLD March 2017 “Current Trends in the Automotive Industry”4
Table of Content
Current challenges of the automotive
industry
Multi-material approach
ComMUnion project
JEC WORLD March 2017 “Current Trends in the Automotive Industry”5
Automotive industry
Some numbers……
Industry, and specifically automotiveindustry, is the 2nd highest source of CO2
emissions in the EU
Europe is playing a very active role in theglobal scenario
EU industry has to meet wider and everincreasing demanding regulations
CO2 EMISSIONS: ONE OF THE MAJOR CHALLENGES TO BE ADDRESSED WORLDWIDE
AN AVERAGE GAP REDUCTION OF 20 GR CO2/km HAS TO BE IMPLEMENTED IN THE NEXT 4 YEARS
SOURCE; Own elaboration based on “European vehicle market
statistics, The International Council on Green Transportation,
Pocketbook 2015/16”
CO2 emissions (passenger cars)
JEC WORLD March 2017 “Current Trends in the Automotive Industry”6
Sector drivers
Each of the value chain actors have their particular drivers
THESE NEEDS ARE TRANSLATED TO THE WHOLE VALUE CHAIN
Globalization represents not only a great opportunity directly related to thegrowth forecasts (100M vehicles will be manufactured by 2020) but also aserious threat due to relocation to cheap labour countries
JEC WORLD March 2017 “Current Trends in the Automotive Industry”7
Towards weight reduction
ALTERNATIVES & COMPETING STRATEGIES
Energy flow. Source; US Government
Mix product/ marketoptimization
More efficient power trains
Aerodynamic improvement(cross sectional area and dragcoefficient)
Weight reduction
5 dm2 2g CO2/km10 kg 1g CO2/km
JEC WORLD March 2017 “Current Trends in the Automotive Industry”8
Material trends
CURRENT MATERIAL TRENDS FOR BODY-IN- WHITE REDUCTION
FUEL CONSUMPTION; 1L/100km
22g/km CO2 EMISSIONS
RENAULT EOLAB
- refined aerodynamics
- lightweight construction
- hybrid powertrain
New developments Market share
JEC WORLD March 2017 “Current Trends in the Automotive Industry”9
Multi-material approach
WEIGHT REDUCTION; requirement translated downstream to EVERY SINGLE COMPONENT
MATERIAL WEIGHT REDUCTION (%) COST
Magnesio 60-75 1.5-2.5
PRFC 50-60 2-10
Aluminio 40-60 1.3-2
Titanio 40-55 1.5-10
PRFV 25-35 1-1.5
HSS 10-15 1
MULTI-MATERIAL DESIGN; overcoming THE COST BARRIER
BASIC PRINCIPLE: Combination of materials of different nature in a single structure, so thatit has the optimum material for each purpose allowing, ultimately, a higherperformance/cost ratio than a bulk material leading to a more efficient resources use.
JEC WORLD March 2017 “Current Trends in the Automotive Industry”10
Multi-material approach
METALLIC- COMPOSITE DISSIMILAR JOINT
Avoid galvanic coupling
Adequate joint resistance
Durability (long term performance)
Thermal fatigue (coef. Thermal expansion)
Manufacturing process (cost effective)
JEC WORLD March 2017 “Current Trends in the Automotive Industry”11
The main
Objective/Consortium
ComMUnion enables productive and cost effective manufacturing of 3D metal/CFRTs multi-materialcomponents. Automatic tape placement of CFRTs with controlled laser-assisted heating, high-speed lasertexturing and cleaning, on-line monitoring and inspection, and computational multi-scale modeling will becombined in a multi-stage robot solution for joining to provide the greatest performance joints. Tools for qualitydiagnosis and decision support will be also implemented under a cognitive approach
Coordinator
Consortium
www.communionproject.eu
JEC WORLD March 2017 “Current Trends in the Automotive Industry”12
The approach
LASER TEXTURING AND CLEANING OF SURFACES
Elimination of undesired substances Creation of controlled structures on the metal
surface for the anchorage of the TPCs.
Polygon scan laser (Source:
FhG-ILT)
Texturized surfaces details (Source: FhG-ILT & AIMEN)
IMPROVED WETTABILITY AND MECHANICAL INTERACTION COMPOSITE-ADHESIVE/METAL
INCREASED
VCSEL heating system (Source: Philips)
Automatic tape placement (Source: FhG-IPT & AIMEN)
Process control (Source: FhG-IPT & AIMEN)
Adjustable heating profile (Source: Philips)
LASER ASSISTED SYSTEM TO HEAT LARGE WIDTH TPCs/ FLEXIBLE HEAD
FOR METAL-COMPOSITE JOINING FOR COMPLEX SHAPES
PRECISE CONTROL OF HEATING DISTRIBUTION ADJUSTMENT TO COMPLEX GEOMETRIES
JEC WORLD March 2017 “Current Trends in the Automotive Industry”13
The approach
PARAMETERIZED ENRICHED CAD/CAM SYSTEM
ON-LINE QUALITY DIAGNOSIS SYSTEM BASED ON NDT’S
CAD/CAM robot planning system applied to tape-laying (Source: http://www.fibrechain.eu/publication/index.jsp)
ENRICHED CAD/CAM- geometry information.- laminate information.- process parameters
DES
IGN
AN
D M
ULT
I-SC
ALE
SI
MU
LATI
ON
SELF-ADAPTIVE SYSTEM
DUAL STAGE NTD’s QUALITY DIAGNOSIS SYSTEM
- Speckle pattern technology for surface condition monitoring
- Active thermography for in-line inspection
PR
OC
ESS
KNOWLEDGE BASE SYSTEM
SELF-ADAPTIVE SYSTEM
ENRICHED CAD/CAM SYSTEM
IDEN
TIFICATIO
N O
F OU
T OF
RA
NG
E STRU
CTU
RES
DECISION SUPPORT SYSTEM (DSS)
DSS: REDUCE THE LEAD TIME IN NEW PRODUCT DESIGNENRICHED CAD/CAM: OPTIMIZE THE SET-UP
CONFIGURATION PROCESS
PREVENT THE DEFECTS PROPAGATION TROUGH THE DIFFERENT STAGES
JEC WORLD March 2017 “Current Trends in the Automotive Industry”14
The impact
IMPACT
At least 20% decrease in the consumption of high cost and critical materials.
At least 30% improvement of product performance.
High level of automation and lower production times compared to current technologies.
Asociación de Investigación
Metalúrgica del Noroeste (AIMEN)
AUTOTECH ENGINEERING, AIE
(AUTOTECH)
AFPT GMBH (AFPT)
New Infrared Technologies SL
(NIT)
TECNATOM S.A. (TECNATOM)
Motofil Robotics, S.A. (MOTOFIL)
Philips GmbH (PHILIPS)
FRAUNHOFER GESELLSCHAFT
ZUR FORDERUNG DER
ANGEWANDTEN FORSCHUNG
EV (FHG)
UNIVERSITY OF PATRAS (LMS)
UNIVERSIDADE DE COIMBRA
(COIMBRA)
Missler Software (MISSLER)
ACITURRI ENGINEERING SL
(ACIENG)
SYM VOULOI KAI PROIONTA
LOGISMIKOU AE (CASP)
LUNOVU GMBH (LUNOVU)
ESI GROUP (ESI)
Thanks for your attention
Consortium
This Project has received funding from the European Union’s
Horizon 2020 research and innovation programme under grant
agreement Nº 680567.
The dissemination of the project herein reflects only the
author’s view and the Commission is not responsible for any
use that may be made of the information it contains.
Dr. Elena Rodriguez| Head of the Advanced Materials Area
Dr. Pilar Rey | ComMunion´s Coordinator
[email protected] | [email protected]
www.communionproject.eu
16www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Which texture?
How to design the assembly?
Classical design process:
1. Perform a surface texturization:
2. Perform assembly process
3. Perform physical testing
• And try another texture if not satisfactory:
• And again, and again
Evolution of surfacetexture
Alternative approach SIMULATE THE EFFECTS OF THE TEXTURIZATION ON THE GLOBAL CRASH BEHAVIOUR
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From geometry/material data to structural data
Extracting the joint properties from the texture pattern
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Demonstration of the method
Mode I Mode II
Increase in effectivestrength and toughness
Sinusoidal material interface texture:
‣ Analyze the impact of texture variationon the effective interface performance
‣ Pure mode I and mode II loading
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Microscopic damage under mode I and mode II loading
Demonstration of the method
• Macroscopic cohesive damage consists of microscopic cohesive and adhesive failure
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Micromechanics Simulation Challenge
Micro- and mesoscopic virtual material characterization
• 3 level simulation challenge:1. Linear, elastic properties
2. Nonlinear, inelastic properties
3. Damage and failure mechanisms
• Goal: Review and compare existing homogenization techniques
• Excellent results found by VPS from ESI Group
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Virtual ManufacturingVirtual
Prototype
Structural performance simulation accounting for process
End to End Virtual Prototyping
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Asociación de Investigación
Metalúrgica del Noroeste (AIMEN)
AUTOTECH ENGINEERING, AIE
(AUTOTECH)
AFPT GMBH (AFPT)
New Infrared Technologies SL
(NIT)
TECNATOM S.A. (TECNATOM)
Motofil Robotics, S.A. (MOTOFIL)
Philips GmbH (PHILIPS)
FRAUNHOFER GESELLSCHAFT
ZUR FORDERUNG DER
ANGEWANDTEN FORSCHUNG
EV (FHG)
UNIVERSITY OF PATRAS (LMS)
UNIVERSIDADE DE COIMBRA
(COIMBRA)
Missler Software (MISSLER)
ACITURRI ENGINEERING SL
(ACIENG)
SYM VOULOI KAI PROIONTA
LOGISMIKOU AE (CASP)
LUNOVU GMBH (LUNOVU)
ESI GROUP (ESI)
Thanks for your attention
Consortium
This Project has received funding from the European Union’s
Horizon 2020 research and innovation programme under grant
agreement Nº 680567.
The dissemination of the project herein reflects only the
author’s view and the Commission is not responsible for any
use that may be made of the information it contains.
Dr. Elena Rodriguez| Head of the Advanced Materials Area
Dr. Pilar Rey | ComMunion´s Coordinator
[email protected] | [email protected]
www.communionproject.eu
23www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.Copyright © ESI Group, 2014. All rights reserved.
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