INTEGRATING COMPOSITE PARTS INTO STEEL / ALUMINIUM BODY · 2016-04-24 · © 2016 by Plasan 1...
24
© 2016 by Plasan 1 INTEGRATING COMPOSITE PARTS INTO STEEL / ALUMINIUM BODY Examining costs and implication on production processes
Transcript of INTEGRATING COMPOSITE PARTS INTO STEEL / ALUMINIUM BODY · 2016-04-24 · © 2016 by Plasan 1...
© 2016 by Plasan 1
INTEGRATING COMPOSITE PARTS INTO STEEL / ALUMINIUM BODY
Examining costs and implication on production processes
© 2016 by Plasan 2 © 2016 by Plasan
ABOUT MYSELF
Coventry University Transport Design Graduate
Chief Designer of Plasan since 2001
Director of Design since 2013
NIR KAHN
© 2016 by Plasan 3 © 2016 by Plasan
World’s leading designer and supplier of lightweight composite/ metal-composite vehicle bodies
ABOUT PLASAN
© 2016 by Plasan 4 © 2016 by Plasan
ABOUT PLASAN
International company with R&D and manufacturing facilities in Israel, US, and France plus broader partner network
© 2016 by Plasan 5 © 2016 by Plasan
ABOUT PLASAN
Over 25,000 vehicles supplied over the last few years at rates of up to 1000/month
ABOUT PLASAN
World’s leading supplier of Class A carbon-fibre automotive parts
CLASS A 40K CARS
PER YEAR
© 2016 by Plasan 6
SRT Viper bonnet photo: SPE Automotive
© 2016 by Plasan 7 © 2016 by Plasan
LEADING THE INDUSTRY
© 2016 by Plasan 7
Paradigm shift for the automotive industry
40K CARS PER YEAR
MASS PRODUCTION FACILITIES
• Grand Rapids, Michigan, USA • Dedicated to mass producing composites for
the automotive industry
© 2016 by Plasan 9
“KITTED HULL” CONCEPT
© 2016 by Plasan 10
KITTED HULL DELIVERY
Wittman regional airport looks like the staging ground for an invasion of Appleton
Jeff Bollier, the Northwestern, October 2009
FEA BACKED BY LIVE TESTING
• Advanced FEA of composite materials • Dynamic simulations
© 2016 by Plasan 12
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
THE FIRST PROPOSAL TO MAKE CARS FROM PRESSED STEEL
© 2016 by Plasan 14
Where is it easy to apply composites? • Hang on parts
• Bolt on or bonded parts
© 2016 by Plasan 14
© 2016 by Plasan 15
SO WHERE SHOULD YOU APPLY COMPOSITES?
Structural Heavy
Strength/ Stiffness Driven
Energy Absorbing
© 2016 by Plasan 16 © 2016 by Plasan
• 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
AVOID OVERCONSOLIDATION
Common wisdom: “save cost through consolidating many parts into a single complex composite component”
May be right for aerospace/ motorsport but is not necessarily correct for mass production
© 2016 by Plasan 17
© 2016 by Plasan 18
APPLYING COMPOSITES TO A RIVBONDED ALU BIW
Pultrusions Metal
composites
RTM
Pressure Press
© 2016 by Plasan 19 © 2016 by Plasan
PULTRUSIONS
Pultrusions can replace aluminium extrusions in many areas of the car
Best to look at it as a system
Can be inserted as reinforcements to pressed metal structure
Very little affect on assembly if bonded
© 2016 by Plasan 20 © 2016 by Plasan
METAL COMPOSITES
Composite materials pressed together with a formed metal part
Allows reduction in metal gauge
Can add or enhance mechanical properties
© 2016 by Plasan 21 © 2016 by Plasan
PRESSURE PRESS
More cost effective than most current CF processes for external panels
Class A finish
High volumes
Exposed weave possible
© 2016 by Plasan 22 © 2016 by Plasan
JOINING
Adhesives
Resins
Tg requirements
High Tg resins/adhesives available but add cost
Compatibility with paint processes
Need to paint?
© 2016 by Plasan 23
SUMMARY
Think purpose, not
component
Heavier and stressed parts have greater
potential
Design for composites
Design for manufacture
