International Conference Moulds Portugal 2004 15-Oct Oct-2004
The Automobile Industry and the Mouldmaking Industry
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
World Ranking - 10 Biggest Automakers Production Volumes 2003 8 7 6 5 4 3 2 1 7.6 6.7 5.9 5.1 4.4 3.1 2.7 2.5 2.5 2.4 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
Volkswagen in 2003 Sales over 5 million vehicles 87,2 billion EUR Over 330.000 employees
Europe Asia-Pacific Region North America Region South America-Africa Africa Region
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
Objectives: Reduced production costs Minimise investment to launch a car
Investment share for a new car 34% 33% 33% Total Investment Tooling Infrastructures Eng. Development
Objectives: Shorter Manufacturing-tocustomer process
Objectives: Developing more niche models more frequently Hatchback Van Coupe Convertible
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
VOLKSWAGEN Semana de Moldes-Conferência Internacional Mário Rodrigues 15-10-2004
PLASTICS
VOLKSWAGEN Polo: front end module
Current vehicles from VOLKSWAGEN with plastic parts: VOLKSWAGEN Phaeton: fender Reaction-Injection-Molding-Technology Hang-on procedure for painting together with the body
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
VOLKSWAGEN Semana de Moldes-Conferência Internacional Mário Rodrigues 15-10-2004
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
SHEET METAL
SHEET METAL
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
COMPOSITES
SMC
VOLKSWAGEN Sheet metal SMC Plastic Semana de Moldes-Conferência Internacional Mário Rodrigues 15-10-2004
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
TENDENCIES
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
Usage of sheetmetal parts 2500 2000 1500 1000 Sheet Metal Parts 500 0 Golf Sharan Passat Cabrio
Percentage of plastic parts 100% 80% 60% 40% 20% 0% 18% Sharan 25% Cabrio
Objectives: Developing more niche models more frequently Hatchback Van Coupe Convertible
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
SHARE OF TYPE OF MATERIALS IN FUTURE CARS Sheet Metal 33% Plastics 34% Compounds 33%
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
STAMPING DIE CONSTRUCTION
Complete Die Set
INJECTION MOULD
Mould Construction
COMPOSITES vs SHEET METAL
COMPOSITES vs SHEET METAL SMC -Sheet Moulding Compound BMC -Bulk Moulding Compound
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
Weight Saving Material Process Part Weight Steel Stamping 3,7 Kg SMC Compress Moulding 2,8 Kg Nylon/PPE Injection Moulding 1,7 Kg
Cost Comparison Example: AUDI A4 convertible decklid 2 modells:europe +US version 4 tools for 2 parts
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
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
Design Flexibility EMI Transparency Example: New VW Cabrio Decklid Antenas for GPS,GSM and AM in the decklid
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 15-10-2004
If you always do what you always done you always get what you always got. Peter Drucker
Thanks