Use of Continuous Fiber Reinforced Engineering Plastics: The Seat Pan of the Opel Astra OPC
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1 Use of Continuous Fiber Reinforced Engineering Plastics: The Seat Pan of the Opel Astra OPC Jörg Schnorr, BASF SE, Dr. Ralf Langendorf, Adam Opel AG, Rüsselsheim, Jordan Kurikov, BASF SE, Ludwigshafen VDI International Congress Plastics in Automotive Engineering Mannheim, März 2013
2 New Applications in Automotive with Fiber Reinforced Engineering Plastics Semi-structural parts Structural parts Ultramid Short fibers Ultramid Structure Long fibers Polyamide with continuous fibers (Tape/Laminate + Overmolding) Developments supported by simulation tool ULTRASIM VDI International Congress Plastics in Automotive Engineering Mannheim, März
3 Continuous Fiber Reinforcement of Injection Molded Parts Types of Semi Finished Products Thermoplastic laminate Organosheet (picture IVW) Heating One Shot Draping and Overmolding Reinforced plastic molding UD Tape Pultruded Tape fully impregnated Laying of tapes (picture AFPT) Reinforcer Reinforced plastic molding VDI International Congress Plastics in Automotive Engineering Mannheim, März
![Stiffness [GPa] Stiffness [GPa] Potential of continuous fiber reinforced plastics Carbon vs.](/docs-images/25/5961662/images/4-0.png "glass fibers --- Stiffness vs. Strength 140 All materials 50 Vol.")
4 Stiffness [GPa] Stiffness [GPa] Potential of continuous fiber reinforced plastics Carbon vs. glass fibers --- Stiffness vs. Strength 140 All materials 50 Vol.-% fiber content UD-Tapes CF 80 Al 60 Mg Laminates 0/90 CF 40 Source: Fiberforge 20 PA-GF50 PA-GF30 Laminates 0/90 GF UD-Tapes GF [MPa] Strength [MPa] VDI International Congress Plastics in Automotive Engineering Mannheim, März
5 BASF and TenCate: Strategic Alliance for Thermoplastic Automotive Composites Joint development and production of thermoplastic composites: UD-tapes and laminates BASF: Know-how in research, production and formulation of thermoplastic resins TenCate Advanced Composites: Expertise in composite manufacturing Advanced tapes and laminates For structural automotive parts (car body, chassis) Focus on mass production VDI International Congress Plastics in Automotive Engineering Mannheim, März
6 Integrative Simulation ULTRASIM for Continous Fiber Reinforced Plastics Process Draping / Molding Measurement Material BASF approach: full ULTRASIM prediction and design level for continuous fiber reinforcement Part VDI International Congress Plastics in Automotive Engineering Mannheim, März
7 Material Characterization for ULTRASIM Laminates and Tapes Tensile Test Orientation Testing Speed (Wallthickness) Humidity 3 Point Bending Puncture Test Compression Test Sheartest Adhesion of Ribs Draping Drapiereigenschaften IVW, Kaiserslautern VDI International Congress Plastics in Automotive Engineering Mannheim, März
8 Ultrasim Helps to Optimize the Design of Plastic Parts ULTRASIM Material modelling - Integrative Simulation Anisotropic Nonlinear Strain-rate sensitive Tension-compression asymmetric Failure modeling Calculate the part right CAE Methods + Mathematical Optimization Process simulation Mechanical simulation Mathematical optimization (parameter, shape, topology) Calculate the right part VDI International Congress Plastics in Automotive Engineering Mannheim, März
9 Ultrasim Predicts Energy Absorption Post Failure Behaviour Ultramid Structure Force 36 Simulation Experiment Way VDI International Congress Plastics in Automotive Engineering Mannheim, März
10 Which Type of Semi Finished Material? Tapes Parts with areas of highest local anisotropic load distribution e.g. front seat backrests Laminates predominantly closed areas, mechanical load rather evenly distributed e.g. seat pans, rear seat backrests, vehicle floors VDI International Congress Plastics in Automotive Engineering Mannheim, März
11 Example: Prototype-Seat Backrest with overmolded Tape Reinforcement Injection molded PA6 UD-Fiber reinforcement Overmolded in injection molding process UD- Fiber reinforcement in high loaded zones Injection molding material in zones of medium load and functional integration VDI International Congress Plastics in Automotive Engineering Mannheim, März
12 Automated Tapelaying Available Processes Moving Head with laser welding fixation Moving Table with ultrasonic fixation VDI International Congress Plastics in Automotive Engineering Mannheim, März
13 Consolidation of Tapes Microscopy und Micro-CT glass fibers matrix: PA6 Ultramid before Consolidation after Consolidation 6-layers: 0 /90 /0 /0 /90 /0 thickness 0,25mm each 60 weight-% glass fibers VDI International Congress Plastics in Automotive Engineering Mannheim, März
14 Component Test and Validation Dynamic Test, 5.0 m/s Impactor Speed CAE Break between bolts in both CAE and Test After Test VDI International Congress Plastics in Automotive Engineering Mannheim, März
15 Energy [J] Drop Tower Test Influence of Fiber Length Ultramid PA6 GF50 23 C Ultramid PA6 LGF40 Structure 23 C Ultramid PA6 CFRT + Reinforcer 23 C Test Temperature 23 C Time [ms] VDI International Congress Plastics in Automotive Engineering Mannheim, März
![Test Temperature 23 C 400 300 200 100 0 0 10 20 30 40 50 60 70 Time [ms] VDI](/docs-images/43/5961662/images/page_15.jpg "International Congress Plastics in Automotive Engineering Mannheim, 13.-14.")
16 Drop Tower Test Influence of Overmolding Material Ultramid 1 Ultramid 2 specific developed impact modified grade Ultramid 2 Ultramid 1 VDI International Congress Plastics in Automotive Engineering Mannheim, März
17 Further Potential in Vehicles Roof Cross Member Cross Car Beam Structural Inserts (A-, B-, C-Pillar, Roof Frame ) Crash Extensions Fire Wall Frontend Structural Floor Battery Integration Structures for doors and hatches, even online paintable VDI International Congress Plastics in Automotive Engineering Mannheim, März
18 Example: Serial Front Seat Pan Opel Astra OPC VDI International Congress Plastics in Automotive Engineering Mannheim, März
19 Example: Serial Front Seat Pan Opel Astra OPC Adam Opel AG SeaTcon AG/ SedisTec UG Reinert Kunststofftechnik Maier Formenbau VDI International Congress Plastics in Automotive Engineering Mannheim, März
20 Serial Front Seat Pan Opel Astra OPC Thermoplastic laminate based on Ultramid PA6 and glass fibers Overmolding material Ultramid PA6 short glass fiber material VDI International Congress Plastics in Automotive Engineering Mannheim, März
21 Ultrasim for Composites Integration of Relevant Process Steps In-Mold Forming Injection Molding Mechanics Integrative Simulation with ULTRASIM VDI International Congress Plastics in Automotive Engineering Mannheim, März
22 Optimization of Heating Parameters Influence parameters: Material properties (absorption, reflection, thermoconductivity etc.) Type of emitter Emitter control (power profile) Distance, time Trials at Krelus Infrared VDI International Congress Plastics in Automotive Engineering Mannheim, März
23 In-Mold-Forming and Overmolding mold closing side IR heater laminate in open mold mold injection side Cycle time 70 sec VDI International Congress Plastics in Automotive Engineering Mannheim, März
24 Micro CT Testing VDI International Congress Plastics in Automotive Engineering Mannheim, März
25 Component Testing m = 25 kg v = 5-9 m/s VDI International Congress Plastics in Automotive Engineering Mannheim, März
26 Seat Testing Quelle: SedisTec VDI International Congress Plastics in Automotive Engineering Mannheim, März
27 Serial Application in Opel Astra OPC Wall thickness 1 mm in laminate 45% weight saving Function integration Cost balance VDI International Congress Plastics in Automotive Engineering Mannheim, März
28 Conclusion Thermoplastic laminates can be used in serial production processes for the automotive industry. Properties of both semi finished material and overmolding material determine part performance. ULTRASIM enables fast development of overmolded continuous fiber parts even in crash relevant applications. Hereby strengths of these materials can be used by far better than with standard methods. Interesting weight and cost results can be reached in automotive seats. VDI International Congress Plastics in Automotive Engineering Mannheim, März
29 Feedback die nahezu perfekten, 18-fach einstellbaren Schalensitze opel-astra-opcflitzlicht-gewitter-aufder-nordschleife html download am VDI International Congress Plastics in Automotive Engineering Mannheim, März
30 Future Outlook Design Freedom with New Materials VDI International Congress Plastics in Automotive Engineering Mannheim, März
31 The information and data given here are based on our current knowledge and experience. This does not relieve the purchaser of our products from incoming inspection. The information and data do not describe the suitability of the product for a specific application. Composition - and durability statements - as well as any other statements are not to be considered as a warranty. The values contained herein are based on analysis/testing of laboratory test specimens and represent data that fall within the normal range of properties for natural materials, unless stated otherwise. Colorants and additives may alter properties. This information is provided as a service for comparative purposes only and in no way constitutes any product specification or the like. For component design the data contained herein are applicable as guideline only. VDI International Congress Plastics in Automotive Engineering Mannheim, März
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