lightweight frp solutions from benteler-sgl...(e.g. rocker lamborghini aventador) (e.g. leaf spring...

Lightweight FRP solutions from

BENTELER-SGL

Economic lightweight design on structural components –

the right material – in the right position – with the right technology Global Automotive Lightweight Materials Detroit 2016

23/08/2016 Robert Hü1er 2

Global Automotive Lightweight Materials Detroit 2016

Agenda

Introduction BENTELER-SGL (BSGL)

Footprint BENTELER Automotive in North America

Examples for actual FRP applications

Reasons for a decision for FRP applications

Main drivers of cost structure of FRP components

Outlook 2020 and main drivers to reach a competitive cost structure

Development example: FRP rear wall in economic lightweight design

Summary



Agenda

Introduction BSGL







Summary


Introduction BENTELER-SGL

Plant Ort

Plant Ried

high volume production (10.000 sqm)

HQ, small vol. production, R&D, technical center

Berlin

VIENNA 1 2

Paris

Berlin London

1.  Ried im Innkreis, Austria 2.  Ort im Innkreis, Austria

50% 50%


Introduction BENTELER-SGL

Carbonfiber Tex,les Braiding Prepregs

Mass Production Plant & Production Engineering

Simulation & Test

BENTELER-SGL is able to apply the fiber Know-How of the SGL Group combined with the High-Mass-Production Know-How at BENTELER Automotive.

BENTELER-SGL is a full service provider to the automotive industry.



Agenda

Introduction BSGL

Footprint BENTELER Automotive and BSGL in North America






Summary



1. Auburn Hills, MI *2001 – Reg. HQ, EO

2. Grand Rapids – Hagen Drive, MI *1979 – Plant, EO

3. Holland, MI *2010 – Plant, EO

4. Kalamazoo, MI *1979 – Plant, EO

5. Goshen, IN *1990 – Plant

6. Spartanburg, SC *2005 – Plant (JIT), Plant

7. Hermosillo, Mexico *2000 – Plant

8. Saltillo, Mexico *1995 – Plant (JIT)

9. Puebla Assembly, Mexico *1992 – Plant, SO, EO

Puebla Assembly, Mexico *2008 – Defense (Plant)

10. Puebla Stamping, Mexico *2010 – Plant



As a full service supplier, BENTELER Automo,ve u=lizes extensive engineering experience, manufacturing know how and vast knowledge of Steels, Aluminum and FRP materials to provide

an op=mized single or mul= material lightweight solu=on to our customers.



Agenda

Introduction BSGL







Summary



Visible Carbon Design Parts Hang-on Performance Parts

Structural components/modules Chassis components

(e.g. Trunk Lid Porsche GT3)

(e.g. Leaf Spring Volvo XC90) (e.g. Rocker Lamborghini Aventador)

(e.g. Sideblade Audi R8)

Responsibility level from „build to print“ to „development responsible“ (product-‐&process design)

23/08/2016 Robert Hü1er 11


Agenda

Introduction BSGL







Summary


Current reasons for a decision for FRP applications

Design reasons (e.g. visible carbon design)

But only a very few FRP projects (e.g. BSGL leaf spring) will be realized because of economic reasons.

Specially for high volume projects, new ways and approaches have to be considered!

Performance reasons (e.g. freedom of geometrical design, maximum lightweight design)

Political/strategic reasons (Management decision for FRP solution, pilot project)

economic decision = cost compe==ve includes the customer specific weight saving bonus (e.g. 10€/kg)

23/08/2016 Robert Hü1er 13


Agenda

Introduction BSGL







Summary


Current cost structure of structural FRP components

2020 2016

45 % Production

process

55% material

Cos

t per

par

t

40-60 €/kg

§  Single or partly automated process steps

§  Manual load and unload §  RTM cycle time 15-20min. §  Partial rework of milled edges §  No chaining of process steps §  Expensive pre- and post-processes

§  C-fiber price 15-16€/kg §  Semi finished material (NCF, woven

fabric) 23-25€/kg §  50% material usage §  Matrix system 4-5€/kg §  diff. additional add on parts and

core materials

§  Mostly designed for metals (Steel, Aluminum …)

§  Low volume projects (<20k sets/à) §  Max. lightweight design §  High degree of security (over design)

level because of lack of experience/know-how

23/08/2016 Robert Hü1er 15


Agenda

Introduction BSGL







Summary



2020 2016

45 % Production

process

55% material

Cos

t per

par

t

40-60 €/kg

35-40% Produc=on process

~ 20 €/kg

60-65% material

Cos

t per

par

t

§  Automated chained process line §  Reduction of pre- and post-

processes §  Processes to work directly with the

fiber into the tool §  Reduction of cycle time §  No manual rework

§  C-fiber price 12-13€/kg §  Focus on material mix (G- & C-fiber) §  >85% material usage §  Matrix system 3-4€/kg §  reduction of additional add on parts

and core materials

§  Single or partly automated process steps §  Load and unload manual work §  RTM cycle time 15-20min. §  Partly rework on milled edges §  No chaining of process steps §  Expensive pre- and post-processes

§  C-fiber price 15-16€/kg §  Semi finished material (NCF, woven fabric)

23-25€/kg §  50% material usage §  Matrix system 4-5€/kg §  diff. additional add on parts and core materials

§  Mostly metal design §  Low volume projects (<20k sets/à) §  Max. lightweight design §  High degree of security level because on lack on

experience/know-how

§  FRP design §  load path design know how §  High volume projects (100k sets/à) §  Max. economic lightweight design §  Reduction of security level to

maximize potential of FRP design

23/08/2016 Robert Hü1er 17


Agenda

Introduction BSGL







Summary

Economic FRP lightweight design Compe,,ve metal design



§  2-shell design §  monolithic material §  4,8kg @ 45€/part

Material Design


Development example: Explanation of the FRP development circle

Input to the Development Circle: §  Knowledge of part properties §  Experience of comparable

applications §  Experience of FRP design §  Know-How to work out the load

path in the component

Input to the Development Circle: §  Knowledge on the whole process

chain §  Experience in automation and

chaining of single process steps §  Know-How of FRP specific

properties for the different processes

Input to the Development Circle: §  Requirments and load cases on the

component §  Full vehicle competence §  Openness to new ways and new

approches

Input to the Development Circle: §  Material characterisation §  Behavior of the different material

combinations §  Requirement on fiber and resin

Development Circle

Placeholder

Process Design Cu

stom

er Rela=

onship

Part Design

A economic compe,,veness of FRP is possible, if all 4 segments are considered during the development process!

Output: §  Identification of the necessary

process steps §  Concept for a most efficient

process chain §  Assessment of maturity level of

the needed processes and definition of development actions to reach the required level



Output: §  Reviewing and adoption of

requirments manual §  Definition of new standards based on

the experiances out of the dev. Phase §  Support on full vehicle questions

Output: §  Material characterisation §  Testing of draping and infusion

behavior §  Curing time optimisation

Placeholder

Process Design Cu

stom

er Rela=

onship

Part Design

Material Design

Output: §  Identification of position and

dimension of load parth §  Positive simulation result §  Amount of material incl. layup plan


Development example: FRP part concept evaluation and definition

G-‐fiber

UD-‐tapes

C-‐fiber

woven / NCF

RTM

prepreg-‐pressing

Towpreg fiber laying

winding

2 shell

FRP + AL

fiber material

CF-‐SMC

recycling fleece

Fiber placement

WP

TFP

load path

reinforcem

ent

target: 20€/kg

general concept surfa

ce

reinforcem

ent



TFP 12-head-equipment à  Carrier fleece in the line à  Separated stacks ready

provided

Fiber placement + Stack handling incl. resin and core

application

Standard wet press cell

Robotic milling cell

Montage cell if needed to mount

add on parts

Cost compe,,veness by: •  Automa=on •  Standardisa=on •  High volume produc=on

Economic FRP lightweight design Compe99ve metal design



§  2-shell design §  monolithic material §  4,8kg @ 45€/part

§  sandwich design §  Load path optimized §  3,2kg @ 62€/part

BENTELER-‐SGL can offer cost compe==ve FRP solu=ons!

23/08/2016 Robert Hü1er 24


Agenda

Introduction BSGL







Summary

the right material – in the right position – with the right technology

2.) Core-process-know-how for short cycle time and technologies to reduce the pre- and post-processes – lean process design


Summary

To reach the target of ~20€/kg, the whole FRP approach has to be changed. Starting with the definition of the best part concept, the approach of the part design has changed into design along the advantages of the different fiber materials (e.g. expensive C-fiber in load path direction, G-fiber in less loaded areas) to design the best economic lightweight part. On the process design side, there has to be a process chain which can combine the optimized fiber combination, fiber usage and a maximum process chaining and automation for the main process steps.

Summary: BSGL can reach the target - focus on two major aspects: 1.) Deep understanding of the requirement of the component in combination with the knowledge of the material properties – load path oriented design


Economic lightweight design on structural components

Robert HüQer Director Sales-‐ & Program Management ___________________________________ Benteler SGL Composite Technology GmbH Fischerstraße 8 A-‐4910 Ried im Innkreis P: +43 7752 82500 569 F: +43 7752 82500-‐3969 M: +43 664 60919-‐569 Mail: robert.hue1er@benteler-‐sgl.com www.benteler-‐sgl.de

Thank you for your attention!

lightweight frp solutions from benteler-sgl...(e.g. rocker lamborghini aventador) (e.g. leaf spring...

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