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Meeting your challenges
Jatsu [email protected]
MATERIALES COMPUESTOS EN AUTOMOCIÓN,
¿CUÁNDO y CÓMO?
BEC, 5th June of 2014
MATERIALES COMPUESTOSEN AUTOMOCIÓN,
¿CUÁNDO Y CÓMO?
• ¿ POR QUÉ ?• ¿ DÓNDE ?
• Why?
• Where?
• When ?
Triad: North America - EU Big 5 – Japan/Korea
Brazil – Russia – India - China
2008
68mn
BRIC
Resto Mundo
Triad 60%
28% 37%
46%
2013
89mn
43%
41%
2018
116mn
The automotive sector grows globallybut moves toward the BRICs countries
CO2 EMMISSIONS REDUCTION BY
AERODYNAMIC PERFORMANCE
Sleek design for greater efficiencyAerodynamic performance means less air resistance, that is lower CO2 emissions
Optimal surface for greater efficiencyAdvanced composites are the main actors in the underbody panels
Up to 5% Cx reduction due to underbody paneling
THE CHALLENGE IS THE
WEIGHT REDUCTION
Light & Safe, the current paradigmFuture cars BIW structures should increase the safety although being lightweight and environmentally friendly
DIFFERENT TECHNICAL SOLUTIONS LOOKING FOR THE SAME GOAL
Advanced steels, still leadersNowadays all OEMs are using new generation steels to increase safety and decrease weight
CASOS NO COMPOSITES
Luxury cars, exotic solutionsSome advanced solutions still are not trends for common cars
Average use of Mg is 2.5 Kg per vehicle 26 Kg in some sportive model
An overview approach should be mandatoryAutomotive is working for minimize the totaldioxide carbon footprint using Eco-Design parameters
Aircrafts, lightweight trends exhibitorAdvanced technologies based onwell known composites solutions
AUTOMOTIVEINDUSTRY
COST EFFICIENCY
Key question for the composite promotingRational use of the technology to ensure the balance between cost and performance
Which is the potential lightweight material?GLOBAL LIGHTWEIGHT AUTOMOTIVE CONFERENCE 2014, May2014, LONDON
COMPOSITES MARKET GROWTH BASED ON ROW MATERIAL & MANUFACTURING PROCESSES COSTS
FIBER REINFORCED PLASTICS (GFRP & CFRP) ARE USED IN STRUCTURAL PARTS
RELATIONSHIP BETWEEN AUTOMOTIVE OEMs AND COMPOSITE MAIN PLAYERS
JUST AN EXAMPLE
McLaren F1
Alfa Romeo 4C
IN COMPOSITES THERE IS ANOTHER SPECIFIC RACE
Sheet
moulding
compound
VISUAL PIECES
Resin transfer
moulding
Pre-preg or
infusion + autoclave
Compression
moulding
Injection
moulding
NON VISUAL PIECES
Compression moulding or
Sheet moulding compound
MECHANICAL COMPONENTS
Group
Stamping dies design and
manufacturing for integral solutions
Design and manufacturing of systems for safety and ergonomics
Design and manufacturing of components for
weight reduction & driving efficiency
Development and manufacturing of
innovative solutions in renewable
energies
1963 1982 2010 2005
BATZ Automotive BATZ Energy
Customers
Group
Worldwide and diversified turnover at the main OEMs
2013 year
Figures 2013 year
BATZ GroupTotal Turnover 222.38 M€
Total Workforce 1.448
Group
Weight reduction, performance optimizing and recyclability in structural parts
Frontend carrierIMC (Injection Moulding Compound), 12 mm
Cockpit carrierGMT (Glass Mat Thermoplastic) GLF (Glass Long Fiber), 25 mm
Floor panelsSMC (Sheet Moulding Compound)
CO2 emissions reduction, optimizing aerodynamic and paneling components
Engine undertray
Deflectors
Body undertray
SMC (Sheet Moulding Compound)
PLASTIC- METAL HYBRID SOLUTIONS
Expertise in Weight Reduction
DESIGN OPTIMIZATION
PEDAL BOX
Through material and technology
The use of advanced materials like polymers in substitution of highly loaded steel parts
requires a careful adaptation of the geometry to maintain the requested performance
Previous VW Polo Pedal Box
Current VW Polo / Audi A1 / … Pedal Box
Several Steel Parts Stamped and Welded together
One Single Polymeric Part (PP+30GF)
Weight BRACKET 1.520 g Weight BRACKET 650 g (-58%)
Cost PEDAL BOX (X) Cost PEDAL BOX (X) – 22%
Expertise in Weight Reduction
DESIGN OPTIMIZATION
PEDAL BOX
Same PPGF material + Optimized Process & Geometry
The use of advanced materials like polymers in substitution of highly loaded steel parts
requires a careful adaptation of the geometry to maintain the required behaviour.
Current AUDI A1 Pedal Box
Case Study – Topological Optimization
Weight BRACKET 650 g Weight BRACKET 495 g (-24%)
Cost BRACKET (Y) Cost BRACKET (Y) – 19%
WIT Reinforcement for Critic Areas
Conventional injection molding
Expertise in Weight Reduction
DESIGN OPTIMIZATION
Weight BRACKET
495 g
-24%
Weight BRACKET
650 g
-58%
Weight BRACKET
1,520 g
Reference
Materials, Process & Geometry optimization
MATERIALES COMPUESTOS EN
AUTOMOCIÓN,
¿POR QUÉ, CUÁNDO, CÓMO y DÓNDE?
• L i g h t e r
• C l e a n e r
• B e t t e r
REFERENCES
