International Conference Moulds Portugal 2004

Transcription

1 International Conference Moulds Portugal Oct Oct-2004

2 The Automobile Industry and the Mouldmaking Industry

3 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

4 World Ranking - 10 Biggest Automakers Production Volumes Nº of cars in Mio 0 General Motors (GM) Ford Toyota-Daihatsu-Hino Volkswagen-Gruppe DaimlerChrysler PSA Peugeot Citroën Honda Hyundai-Kia Nissan-Nissan Diesel Fiat-Iveco

5 Volkswagen in 2003 Sales over 5 million vehicles 87,2 billion EUR Over employees

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7 Europe Asia-Pacific Region North America Region South America-Africa Africa Region

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9 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

10 Objectives: Reduced production costs Minimise investment to launch a car

11 Investment share for a new car 34% 33% 33% Total Investment Tooling Infrastructures Eng. Development

12 Objectives: Shorter Manufacturing-tocustomer process

13 Objectives: Developing more niche models more frequently Hatchback Van Coupe Convertible

14 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

15 VOLKSWAGEN Semana de Moldes-Conferência Internacional Mário Rodrigues

16 PLASTICS

17 VOLKSWAGEN Polo: front end module

18 Current vehicles from VOLKSWAGEN with plastic parts: VOLKSWAGEN Phaeton: fender Reaction-Injection-Molding-Technology Hang-on procedure for painting together with the body

19 Current vehicles from VOLKSWAGEN with plastic hang-on-parts: VOLKSWAGEN New Beetle: fender Injection-Molding Technology Hang-on procedure for painting together with the body

20 VOLKSWAGEN Semana de Moldes-Conferência Internacional Mário Rodrigues

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22 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

23 SHEET METAL

24 SHEET METAL

25 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

26 COMPOSITES

27 SMC

28 VOLKSWAGEN Sheet metal SMC Plastic Semana de Moldes-Conferência Internacional Mário Rodrigues

29 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

30 TENDENCIES

31 Usage of Plastic and Compounds vs Sheet Metal Parts 100% 80% 60% 40% %Total Parts %Other Parts 18% Total Parts Other Parts 24.8% 20% 0% Car 1990 Others Plastics Car 2004 Others Plastics

32 Usage of sheetmetal parts Sheet Metal Parts Golf Sharan Passat Cabrio

33 Percentage of plastic parts 100% 80% 60% 40% 20% 0% 18% Sharan 25% Cabrio

34 Objectives: Developing more niche models more frequently Hatchback Van Coupe Convertible

35 For niche models we need: Less Design time Less Prototype time Less Tooling time New Materials for the final parts New Processes of Manufacturing Stamping Tools New Processes of Manufacturing Injection Moulds

36 SHARE OF TYPE OF MATERIALS IN FUTURE CARS Sheet Metal 33% Plastics 34% Compounds 33%

37 1.Volkswagen 2.Objectives 3.How a car is done a) Plastic parts b) Sheet Metal parts c) Composites 4.Preparing the Future a) Tendencies b) Composites vs Sheet Metal

38 STAMPING DIE CONSTRUCTION

39 Complete Die Set

40 INJECTION MOULD

41 Mould Construction

42 COMPOSITES vs SHEET METAL

43 COMPOSITES vs SHEET METAL SMC -Sheet Moulding Compound BMC -Bulk Moulding Compound

44 WHY SMC? Weight saving Investment cost Design Flexibility EMI transparency Dent Resistance E-Coat compatibility (on-line paintable) Intrinsic corrosion Resistance Recyclable Dimensional stability Class-A surface finish

45 Weight Saving Material Process Part Weight Steel Stamping 3,7 Kg SMC Compress Moulding 2,8 Kg Nylon/PPE Injection Moulding 1,7 Kg

46 Cost Comparison Example: AUDI A4 convertible decklid 2 modells:europe +US version 4 tools for 2 parts

47 Cost comparison inner decklid A4 SMC Steel Tools: 1 Cycle Time 2,5 min Tool Cost: 0,4 Mill. Tools: 5 Cycle Time 20 Sec Tool Cost: 2,0 Mill. Output: 540 p/d* Output: 6700 p/d* * 3shifts / day

48 Cost comparison outer decklid A4 SMC Steel Tools: 3 Cycle Time 2,5 min Tool Cost: 1,2 Mill. Tools: 15 Cycle Time 20 Sec Tool Cost: 6,0 Mill. Output: 540 p/d* Output: 6700 p/d* * 3shifts / day

49 Design Flexibility EMI Transparency Example: New VW Cabrio Decklid Antenas for GPS,GSM and AM in the decklid

50 VOLKSWAGEN Cars using the technology Citröen/Peugot/Fiat/Lancia SMC Tailgate Mercedes CL class SMC decklid Maybach 57 and 62 New VW Cabrio SMC decklid Semana de Moldes-Conferência Internacional Mário Rodrigues

51 If you always do what you always done you always get what you always got. Peter Drucker

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54 Thanks