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DALIA TAYLOR, ABDEL-FATTAH M. SEYAM, NANCY B. POWELL,
MANSOUR H. MOHAMED
THREE-DIMENSIONAL ORTHOGONALWOVEN COMPOSITES INCORPORATION IN
THE AUTOMOTIVE SUPPLY CHAIN
COLLEGE OF TEXTILES, NC STATE UNIVERSITY
RALEIGH, NC, USA
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AUTOMOTIVE INDUSTRY DRIVES:
RAW MATERIALS development
FINANCIAL systems
ADVANCED MATERIALS and manufacturing improvements
SAFETY ENERGY
ENVIRONMENTAL innovations
Forecasting in 2005: 70,000,000 per year in 2010, from 55,000,000 in 2000
2008: 74,647,260 in production and 71,900,856 in sales
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Source: Americas Auto Industry, 2006
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Source: Global Market Data Book, 2008
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MAJOR DRIVERS OF THE AUTOMOTIVE
INDUSTRY
global CONSUMERS expectations
GOVERNMENT regulations: safety and environmental
issues
development and changes in TECHNOLOGY
COST pressures
THE NEED TO PRODUCE SAFE AND
COST EFFECTIVE LIGHTWEIGHT
VEHICLES HAS BEEN IDENTIFIED
AS CRITICAL!Source: Veloso, 2000; Powell, 2004; Banisster, 2004
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THE TRANSFORMATION OF THE SUV
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425 % ofWEIGHT reduction would
save ~13% of the total U.S. gasoline
consumption and would reduce CO2
emission by 101 million tons per year
75% ofENERGY consumption is
directly related to WEIGHT
SUV average millage is 21.7 MPG
SMALL CAR millage is 32 MPG
Source: Korth, 2007
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OBJECTIVE OF THE RESEARCH
REPLACE heavy METAL PARTS with LIGHTWEIGHT 3Dorthogonal woven COMPOSITES made from fiberglass
APPROACH PERFORMANCE characteristics ofVEHICLE
body with the newly created lighter and strongerCOMPOSITES
RELATE the PERFORMANCE of the 3D woven fabric
composite to woven CONTRUCTION PARAMETERS
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BENEFITS OF LIGHT WEIGHT COMPOSITES
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 ofRECYCLABILITY
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BENEFITS OF 3D WOVEN COMPOSITES
excellent ability to TRANSFER polymeric RESIN much
faster than equivalent thickness stack of 2-D fabrics HYBRIDIZATION ofDIFFERENT FIBER types in the
weaving process
ability to produce COMPLEX SHAPES (I, T, box, etc.)
ability to CONTROL Z-FIBER VOLUME FRACTIONfrom extremely low (1%) to extremely high levels (60%) tomeet specified demand
NOT susceptible to DELAMINATING
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Source: www.3tex.com
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VEHICLE BODY AND CHASSIS STRUCTURE
Source: www.carbodydesign.com
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3WEAVETM
Source: www.3tex.com
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3D WOVEN FABRIC FORMATION
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MULTIPLE FILLINGS INSERTION
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EXAMPLES OF FORMS MADE BY 3D WEAVING
Source: www.3tex.com
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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
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Source: Acheson et al, 2004
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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
Source: prepared by B. Schartow
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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
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RESEARCH APPROACH
CONSTRUCTION PARAMETERS (variables)
filling linear density
filling roving linear density
arrangements of warp and Z-yarns
number of warp and filling layers (structure)
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ARRANGEMENTS OF WARP AND Z-YARNS
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1z/1w (plain weave) 1z/2w (plain weave)1z/1w (basket weave)
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RESEARCH APPROACH
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
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BENEFITS TO AUTOMOTIVE APPLICATIONS
STRENGTH LIGHTWEIGHT
improved FUEL EFFICIENCY and C02 EMISSION
decreased PROCESSING TIME
increased QUALITY
CORROSION resistance
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INTEGRATION OF NEW TEXTILE
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INTEGRATION OF NEW TEXTILE
TECHNOLOGY
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Changes may occur in automotive supply chain
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AUTOMOTIVE SUPPLY CHAIN STRUCTURE
Source: Tassey et al, 1999
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SUPPLY CHAIN NETWORKS
Source: Swaminathan et al, 1998
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AUTOMOTIVE DESIGN AND DEVELOPMENT
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AUTOMOTIVE DESIGN AND DEVELOPMENT
PROCESS
Source: Tassey et al, 1999
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CHANGES IN AUTOMOTIVE DESIGN AND
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CHANGES IN AUTOMOTIVE DESIGN AND
DEVELOPMENT PROCESS
Source: adapted from Tassey et al, 1999
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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
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REFERENCES
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Americas Auto Industry. (2006). Economic Contributions & CompetitiveChallenges. Retrieved June 14, 2007, from
http://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdf
Banisster, M. K. (2004). Development and Application of AdvancedTextile Composites. Proceedings of the Institution of Mechanical Engineers.Vol. 218 Part L: Journal of Materials: Design and Applications. p. 253-260.
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 Materialsin Automotive Interiors. Journal of Textile and Apparel, Technology andManagement, 3 (4). Retrieved April 2, 2007, fromhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdf
Swaminathan, J., M. Smith, S., F., Sadeh, N., M. (1998). Modeling SupplyChain Dynamics: A Multiagent Approach. Decision Science, Vol. 29 (3),p. 607-632.
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http://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdfhttp://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdfhttp://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdfhttp://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdfhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdfhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdfhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdfhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdfhttp://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdfhttp://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdfhttp://www.autotradecouncil.org/Images/Economic%20contribution%20content.pdf -
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REFERENCES
Tassey, G., Brunnermeier, S., B., Martin, S., A. (1999). InteroperabilityCost Analysis of the U.S. Automotive Supply Chain. Research Triangle
Institute, Project Number 7007-03, North Carolina. Veloso, F. (2000). The Automotive Supply Chain Organization: Global
Trends and Perspectives. Working Paper. Massachusetts Institute ofTechnology.
www.3tex.com, Retrieved March 21, 2008
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