THREE-DIMENSIONAL ORTHOGONAL WOVEN COMPOSITES INCORPORATION IN THE AUTOMOTIVE SUPPLY CHAIN

Transcription

1 THREE-DIMENSIONAL ORTHOGONAL WOVEN COMPOSITES INCORPORATION IN THE AUTOMOTIVE SUPPLY CHAIN DALIA TAYLOR, ABDEL-FATTAH M. SEYAM, NANCY B. POWELL, MANSOUR H. MOHAMED COLLEGE OF TEXTILES, NC STATE UNIVERSITY RALEIGH, NC, USA

2 AUTOMOTIVE INDUSTRY DRIVES: 2 RAW MATERIALS development FINANCIAL systems ADVANCED MATERIALS and manufacturing improvements SAFETY ENERGY ENVIRONMENTAL innovations Source: America s Auto Industry, 2006 Forecasting in 2005: 70,000,000 per year in 2010, from 55,000,000 in : 74,647,260 in production and 71,900,856 in sales Source: Global Market Data Book, 2008

3 MAJOR DRIVERS OF THE AUTOMOTIVE INDUSTRY global CONSUMERS expectations GOVERNMENT regulations: safety and environmental issues development and changes in TECHNOLOGY COST pressures 3 THE NEED TO PRODUCE SAFE AND COST EFFECTIVE LIGHTWEIGHT VEHICLES HAS BEEN IDENTIFIED AS CRITICAL! Source: Veloso, 2000; Powell, 2004; Banisster, 2004

4 THE TRANSFORMATION OF THE SUV 75% of ENERGY consumption is directly related to WEIGHT SUV average millage is 21.7 MPG SMALL CAR millage is 32 MPG 4 25 % of WEIGHT reduction would save ~13% of the total U.S. gasoline consumption and would reduce CO2 emission by 101 million tons per year Source: Korth, 2007

5 OBJECTIVE OF THE RESEARCH 5 REPLACE heavy METAL PARTS with LIGHTWEIGHT 3D orthogonal woven COMPOSITES made from fiberglass APPROACH PERFORMANCE characteristics of VEHICLE body with the newly created lighter and stronger COMPOSITES RELATE the PERFORMANCE of the 3D woven fabric composite to woven CONTRUCTION PARAMETERS

6 BENEFITS OF LIGHT WEIGHT COMPOSITES 6 LIGHTER weights high IMPACT resistance and STRENGTH to weight ratio increased PRODUCTIVITY (more productive line with the same labor and equipment) decreased PROCESSING TIME and higher QUALITY (saving labor and cycle time, less assembling errors) COST effectiveness speed of RECYCLABILITY

7 BENEFITS OF 3D WOVEN COMPOSITES 7 excellent ability to TRANSFER polymeric RESIN much faster than equivalent thickness stack of 2-D fabrics HYBRIDIZATION of DIFFERENT FIBER types in the weaving process ability to produce COMPLEX SHAPES (I, T, box, etc.) ability to CONTROL Z-FIBER VOLUME FRACTION from extremely low (1%) to extremely high levels (60%) to meet specified demand NOT susceptible to DELAMINATING Source:

8 VEHICLE BODY AND CHASSIS STRUCTURE 8 Source:

9 3WEAVE TM 9 Source:

10 3D WEAVING MACHINE 10

11 3D WOVEN FABRIC FORMATION 11

12 MULTIPLE FILLINGS INSERTION 12

13 EXAMPLES OF FORMS MADE BY 3D WEAVING 13 Source:

14 VACUUM-ASSISTED RESIN TRANSFER MOLDING (VARTM) TECHNOLOGY 14 Source: Acheson et al, 2004

15 VACUUM-ASSISTED RESIN TRANSFER MOLDING (VARTM) TECHNOLOGY 15 Source: prepared by B. Schartow

16 VACUUM-ASSISTED RESIN TRANSFER MOLDING (VARTM) TECHNOLOGY 16

17 RESEARCH APPROACH 17 CONSTRUCTION PARAMETERS (variables) filling linear density filling roving linear density arrangements of warp and Z-yarns number of warp and filling layers (structure)

18 ARRANGEMENTS OF WARP AND Z-YARNS 18 1z/1w (plain weave) 1z/1w (basket weave) 1z/2w (plain weave)

19 RESEARCH APPROACH 19 The TESTED PROPERTIES include: Fiber content Heat deteriorate temperature (HDT) Tensile strength, modulus, and elongation Flexural strength and modulus Charpy impacts (notched and unnotched) Dynatup impact

20 BENEFITS TO AUTOMOTIVE APPLICATIONS 20 STRENGTH LIGHTWEIGHT improved FUEL EFFICIENCY and C02 EMISSION decreased PROCESSING TIME increased QUALITY CORROSION resistance

21 INTEGRATION OF NEW TEXTILE TECHNOLOGY Changes may occur in automotive supply chain 21

22 AUTOMOTIVE SUPPLY CHAIN STRUCTURE 22 Source: Tassey et al, 1999

23 SUPPLY CHAIN NETWORKS 23 Source: Swaminathan et al, 1998

24 AUTOMOTIVE DESIGN AND DEVELOPMENT PROCESS 24 Source: Tassey et al, 1999

25 CHANGES IN AUTOMOTIVE DESIGN AND DEVELOPMENT PROCESS 25 Source: adapted from Tassey et al, 1999

26 CONCLUSIONS CHANGES IN AUTOMOTIVE SUPPLY CHAIN AFTER INCORPORATION OF 3D WOVEN COMPOSITES: reduced jobs in automotive industry, but increased in textiles; created new business decreased size of the automotive supply chain decreased time to the market changed position of textile industry in supplying fibers components 26

27 REFERENCES 27. America s Auto Industry. (2006). Economic Contributions & Competitive Challenges. Retrieved June 14, 2007, from nt.pdf Banisster, M. K. (2004). Development and Application of Advanced Textile Composites. Proceedings of the Institution of Mechanical Engineers. Vol. 218 Part L: Journal of Materials: Design and Applications. p Korth, K. Key Issues for Suppliers: Navigating a Challenging Landscape. OESA Cincinnati Regional Meeting. Dec. 6, 2007 Powell, N. B. (2004). Design Driven: The Development of New Materials in Automotive Interiors. Journal of Textile and Apparel, Technology and Management, 3 (4). Retrieved April 2, 2007, from Swaminathan, J., M. Smith, S., F., Sadeh, N., M. (1998). Modeling Supply Chain Dynamics: A Multiagent Approach. Decision Science, Vol. 29 (3), p

28 REFERENCES Tassey, G., Brunnermeier, S., B., Martin, S., A. (1999). Interoperability Cost Analysis of the U.S. Automotive Supply Chain. Research Triangle Institute, Project Number , North Carolina. Veloso, F. (2000). The Automotive Supply Chain Organization: Global Trends and Perspectives. Working Paper. Massachusetts Institute of Technology. Retrieved March 21,