integrating composite parts into steel / aluminium body · 2016-04-24 · © 2016 by plasan 1...
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© 2016 by Plasan 1
INTEGRATING COMPOSITE PARTS INTO STEEL / ALUMINIUM BODY
Examining costs and implication on production processes
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© 2016 by Plasan 2 © 2016 by Plasan
ABOUT MYSELF
Coventry University Transport Design Graduate
Chief Designer of Plasan since 2001
Director of Design since 2013
NIR KAHN
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© 2016 by Plasan 3 © 2016 by Plasan
World’s leading designer and supplier of lightweight composite/ metal-composite vehicle bodies
ABOUT PLASAN
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© 2016 by Plasan 4 © 2016 by Plasan
ABOUT PLASAN
International company with R&D and manufacturing facilities in Israel, US, and France plus broader partner network
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© 2016 by Plasan 5 © 2016 by Plasan
ABOUT PLASAN
Over 25,000 vehicles supplied over the last few years at rates of up to 1000/month
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ABOUT PLASAN
World’s leading supplier of Class A carbon-fibre automotive parts
CLASS A 40K CARS
PER YEAR
© 2016 by Plasan 6
SRT Viper bonnet photo: SPE Automotive
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LEADING THE INDUSTRY
© 2016 by Plasan 7
Paradigm shift for the automotive industry
40K CARS PER YEAR
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MASS PRODUCTION FACILITIES
• Grand Rapids, Michigan, USA • Dedicated to mass producing composites for
the automotive industry
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“KITTED HULL” CONCEPT
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KITTED HULL DELIVERY
Wittman regional airport looks like the staging ground for an invasion of Appleton
Jeff Bollier, the Northwestern, October 2009
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FEA BACKED BY LIVE TESTING
• Advanced FEA of composite materials • Dynamic simulations
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TRANSFERRING KNOW-HOW & TECHNOLOGY
Applying principles that successfully moved military vehicles from welded bodies to multi-material architecture
Strength, safety, weight, and cost driven
Efficient use of the more expensive materials
Performance
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THE FIRST PROPOSAL TO MAKE CARS FROM PRESSED STEEL
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Where is it easy to apply composites? • Hang on parts
• Bolt on or bonded parts
© 2016 by Plasan 14
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SO WHERE SHOULD YOU APPLY COMPOSITES?
Structural Heavy
Strength/ Stiffness Driven
Energy Absorbing
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• Cost per kg saved is lower the harder the part is working
• Design architecture to concentrate loads in these areas
• Design parts for production with processes that are cost effective for composites
COST/KG SAVED
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AVOID OVERCONSOLIDATION
Common wisdom: “save cost through consolidating many parts into a single complex composite component”
May be right for aerospace/ motorsport but is not necessarily correct for mass production
© 2016 by Plasan 17
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APPLYING COMPOSITES TO A RIVBONDED ALU BIW
Pultrusions Metal
composites
RTM
Pressure Press
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PULTRUSIONS
Pultrusions can replace aluminium extrusions in many areas of the car
Best to look at it as a system
Can be inserted as reinforcements to pressed metal structure
Very little affect on assembly if bonded
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METAL COMPOSITES
Composite materials pressed together with a formed metal part
Allows reduction in metal gauge
Can add or enhance mechanical properties
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PRESSURE PRESS
More cost effective than most current CF processes for external panels
Class A finish
High volumes
Exposed weave possible
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JOINING
Adhesives
Resins
Tg requirements
High Tg resins/adhesives available but add cost
Compatibility with paint processes
Need to paint?
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SUMMARY
Think purpose, not
component
Heavier and stressed parts have greater
potential
Design for composites
Design for manufacture