Les procédés composites grandes cadences
A quel prix ?
Guillaume CHAMBON ([email protected])
Techno Campus Composites - 09 / 02 / 2017
Agenda
2
1 Faurecia Composite Technologies
2 Benchmark
3 Acting the Composite value chain
4 Conclusion
4
Faurecia Clean MobilityComposite Technologies, a division of Faurecia’s strategy in Clean Mobility
Innovations
Passenger cars emission controlCV
on-Highway
Exhaust Energy Recovery Innovations
LightweightInnovations
Exhaust Energy Recovery Innovations
LightweightInnovations
CV
off-HighwayHigh Horse Ppwer
Lightweight composite solutionsEnergy Recovery
for Electrical Vehicle
Real Time Data Fuel Cell Technology
CV Off-highway and HHP Adjacent clean solutions for EV
Air Quality Innovations: Heated Catalyst, ASDS, Turbo Gas, EGR
Current business – Traditional portfolio
Building blocks towards Cleaner Solutions
#1 worldwide in mechanisms & seats structure
#3 worldwide in complete seats
#1 worldwide interior vehicle
#1 worldwide in emissions control technologies
A global leader in its 3 activities
Drive the transformation of the global Mobility Value Chain towards Cleaner Solutions
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Faurecia Composite TechnologiesA transversal center of expertise for Faurecia Group activities
5
InteriorsSeating Clean Mobility
o Heat Shields
o Temp. resistance
o Acoustic / NVH
o Functional integration
o H2 tanks
o Seat Structures
o Luggage crash
o Aspect (B-side)
o Acoustic / NVH
o Functional
integration
o A-class body
o Closures
o Rear/side crash
test
o Functional
integration
o Semi-structural & Structural
o Crash resistance &
absorption
o Stiffness & Rigidity
o Underbody / Aero & Skid
Shields
o Acoustic / NVH
o Impact resistance
o Cross-car Beam
o Crash
EV
o Battery Protection
o Crash absorption
o Heat resistance
o Fnct. integration
o A-class
o Semi- & Structural
o Painting
o Functional
integration
Body
Customers
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
BMW case study
7
2013 2014 2016
BIW combining steel / aluminum / CFRP
16 CFRP parts
BMW i3 BMW i8 BMW 7-series
Towards an architecture including composites ‘just-where-needed’
instead of a complete BIW in composite
Oct 2016: BMW announces
they will limit the use of CF,
turning instead to lightweight
steel to keep profit.
CF Life Module (BIW / Life Module)
Aluminium Drive Module
Life Module
Drive Module
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Metal : Magna Example
Ultralight door architecture with 42.5% weight savings
Extensive use of aluminum
“Contributions in the area of molding techniques and polymers represented
approximately 7% of the total mass reduction”
“The target in terms of cost was approximately $5 per pound and we came in at
$2.59 per pound”
Status on compositesBenchmark
Composite application in mass market is not established
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Ultralight Door Module - Magna
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Status on compositesThe composite value chain
Mandatory to act on multiple levers of the composite value chain
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Expectation
Lever - Reduce raw
material price
- Reduce semi-
finished products
- Material compliance
with quick
processes
- Tailored mechanical
performance
- Speed
- Reduce waste
- Reduce scrap
- Reduce post molding
activities
- Automation
- Tailored design
- Function integration
- Hybrid assembly
- Speed
- Reliability
- Reduced trial
number
- Increase material
knowledge &
accuracy
- Engineering &
Development time
reduction
- Global costing
approach
Raw material
Process Product Assembly Engineering
€ € € € €
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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1 Faurecia Composite Technologies
2 Benchmark
3 Acting the Composite value chain
4 Conclusion
Raw material
Process Product Assembly Engineering
Current trend is to reduce carbon cost to ~ 13€/kg
Next steps :
Working on the carbon fiber value chain to reduce useless steps
2020: OakRidge US National lab: 11€/kg
2023: FORCE : 8€/kg
MaterialCarbon price reduction
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Carbon fiber cost divided by 2 over a duration of 8 years
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Reduce semi-finished products usage
Cost
Geometry freedom
Fenefit from specific material property
Thermoplastic RTM Example
In mold combination of dry fabrics and resin
Integration of ribs
Very high fluidity of caprolactam grants a better fiber impregnation
Opportunity to increase fiber content ratio
Net-shape part production
MaterialMove up the material value added chain
13Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Fast Cure application on current production case
MaterialWorking on material to reduce cycle time
14
Potential to reduce even more but bottleneck : Surrounding operations of the closed mold phase
Closed press 21’10’’Open press
2’00’’
Preform
introduction
2’00’’
Mold
closing
0’35’’Closed mold 20’00’’
Mold
opening
0’35’’
Deburring
1’30’’
Weighing
0’30’’
Next
preform
preparation
3’30’’
Operator is waiting 15’00’’
Open press 6’00’’
Demolding
3’30’’Shaper
0’30’’
Mold cleaning
2’00’’
Initial cycle time 29’10’’
Closed press 6’40’’Open press
2’00’’
Preform
introduction
2’00’’
Deburring
1’30’’
Weighing
0’30’’
Next
preform
preparation
3’30’’
Fast cure cycle time 14’40
Mold
closing
0’35’’
Mold
opening
0’35’’
Demolding
3’30’’Shaper
0’30’’
Mold cleaning
2’00’’
Closed mold
5’30’’
Open press 6’00’’
Operator is waiting 0’40’’
Time cycle / 2
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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1 Faurecia Composite Technologies
2 Benchmark
3 Acting the Composite value chain
4 Conclusion
Raw material
Process Product Assembly Engineering
Fast Form
2 min cycle time
High dimension preforms (up to 3m²)
Stamping
Automatic fibre placement
ProcessFast preform & Automation
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Fully automated process compliant with automotive mass market
Automation example in plants : 2 SMC parts every 90sec
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
17
1 Faurecia Composite Technologies
2 Benchmark
3 Acting on the Composite value chain
4 Conclusion
Raw material
Process Product Assembly Engineering
Function integration
Benefit of shape freedom
Speak at higher level in the development V-cycle
Move from black metal approach
Benefit of tailored design opportunities
Put the right material at the right place
Playing on
Stacking sequence
Glass / carbon mix
Reinforcement volume ratio
Overmolding
ProductReduce cost and weight
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Benefit of highly adaptability of composites
Global spec.
Architecture.
Detailed spec.
Detailed design
Unitary test
Integration
test
Validation test
Time
Deta
ils
Function
integration
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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1 Faurecia Composite Technologies
2 Benchmark
3 Acting the Composite value chain
4 Conclusion
Raw material
Process Product Assembly Engineering
Hybrid assembly
Magnetic Pulse Spot welding
Benefits
Metal insert ok for manufacturing (easier than )
Compatible with multi-material welding with BIW : steel, steel+zinc, aluminum…
Few modification at OEM assembly line
Assembly
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Quick assembly solution compatible with hybrid materials
Coil
Flyer Sheet
with HumpComposite Plate with
Metallic Insert inside
Air gap Welding
Metallic Insert Steel
Steel + Zinc: e≈0,49µm
Zinc: e≈3,8 µm
Alu + Zinc: e≈3,5 µm
Alu
Welding analysis : perfect adhesion
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Composite Assembly
Assembly
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US welding solution chosen for TP Composite assembly
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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1 Faurecia Composite Technologies
2 Benchmark
3 Acting the Composite value chain
4 Conclusion
Raw material
Process Product Assembly Engineering
EngineeringEnhanced Engineering scheme
23
If n
ot
OK
Important evaluation
times
No process – product
coupling
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Negligible computation time increase by process and costing consideration
Mechanical simulation and costing predictions enhanced with Process Estimator outcome
EngineeringExample of part optimization
7 zones with independent material lay-up
UD and chopped fiber material (carbon & glass)
Zones defined using topology optimizations with an isotropic material
Main process parameter is the injection time (fixed curing time)
Optimization results:
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Important part cost reduction with process consideration
Standard approach Enhanced approach
Part mass: + 5 %
Part filling time: - 96 %
Total cycle time: - 29 %
Total part cost: - 10 %
1
0
0
&
100 %
1
0
0
&
100 %
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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SB63G1-T1.5 HSR 45-degree angle
0
50
100
150
200
250
0 5 10 15 20 25
Strain (%)
Str
ess
(M
pa
)
HSR Tensile 45° 23C - 0.1 s-1
HSR Tensile 45° 23C - 2 s-1
HSR Tensile 45° 23C - 28 s-1
HSR Tensile 45° 23C - 50 s-1
HSR Tensile 45° 23C - 170 s-1
Optimization
Crash / Energy absorption :
Manufacturing
PROCESS
Raw Materials
And
Sub-Process
PRODUCT
Design Assemblies
Pre-forming / wrapping
Thermoforming
Composite / Composite or
Composite / Metal
Material Laws
SIMULATION applied to COMPOSITES
Engineering
Optimization Optimization
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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EngineeringProduct & Process link
Thermoforming simulation
Process simulation results,
Input for product simulation
Trial
Trial
Product simulation without process consideration
Product simulation with process consideration
Mandatory to consider product-process dependency for complex parts
Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
Composite deployment in Automotive mass market is not established.
Important cost reduction and development of efficient engineering tools mandatory
Mandatory to act on multiple levers in the composite value chain.
Conclusion
28Procédés composites grandes cadences
Technocampus Composites – 2017-02-09
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