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Design and structural simulation of composites in transportationDesign and structural simulation of composites in transportation28th June 2002, Genoa, Italy28th June 2002, Genoa, Italy

The use of composite materialsThe use of composite materialsin vehicle designin vehicle designEnrico Mangino, Enrico Indino

Centro Ricerche Fiat is the sole owner of this document. It cannot be copied or given to third parties without permission.Design and structural simulation of composites in transportation - 28th June 2002, Genoa, ItalyThe use of composite materials in vehicle design, E. Mangino, E. Indino

Index

The presentation will deal about:Automotive industry driversComposites in AutomotiveTP vs. TSWhy composites?Composites simulation exampleConclusions

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Market and regulations

THE MARKET

Price competitivenessMaintenance economyQuality, reliabilitySecurity, performancesDifferentiation, brand policyCustomisation, use versatilityFrequent and fast model changeEnvironmental feeling

REGULATIONS

Security(vehicle occupants, people on the roads)

Environment(production, vehicle use, end of life)

Fiat Multipla

Lancia Y

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EMISSION REDUCTION(CO2 reduction CAFE target)

Emission regulations

167,5

140

120110

120

130

140

150

160

170

2003 2008 2012

CO

2 [

g/km

]

Years

Modifications of power-trainVehicle weight reduction

Need of new materials andtechnologies for lightening

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END OF LIFE REGULATION(cars, light commercial and three wheels vehicles)

Recycling and re-useRecovery Landfill

Target 20065%

80%

15%

Target 201510%

85%

5%

Without controlor unknown

EC current foreseen

92,5%

7,5%

?

Re-use: use of an old vehicle component for the same application as the original

Recycling: treatment of used materials for same or different production (except energy)

Recovery: treatment of used materials for energy production

Recycling regulations

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Composites

COMPOSITESCOMPOSITESMaterials composed by a matrix with fibres bundles as reinforcements

Matrix may be metallic, polymeric or ceramic

Usually, speaking about structural composites,we think about thermoset matrixes

In Automotive industryAutomotive industry it is not always true:thermoplastic matrixesthermoplastic matrixes are very widespread

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0,00%

2,00%

4,00%

6,00%

8,00%

10,00%

1950 1960 1970 1980 1990 2000

1100 5001300/1500

850124

128

127

131

PANDAUNO

THEMATIPO

DEDRACINQUECENTO

PUNTOBRAVO/A

MAREA

PRISMARITMO

Source: Fiat Auto

Polymeric materialsFiat cars

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Thermoplastic composites

In the Automotive industry most used TP matrixes are:Polypropylene (PP)Polyamide (PA)ABSPC+ABS

Typical reinforcements are:glass fibresmineral filler (talcum)vegetal fibres

.. typically produced using injection moulding

Lancia Y

Fiat Coupè

Mercedes Benz Travego

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Thermoset composites

Typical thermoset resins have polyester matrixes …

… most of the times they are used to producedstructural/functional components.Production processes are injection (BMC, ZMC) and compression (SMC)

There are also applications with other matrixes:PUPVC

Usually they have aesthetic applications likefoams, paintings, coatings … but not always

Iveco Stralis

Fiat Stilo

Renault Espace

Fiat Ulysse

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Thermoset panels

THERMOSET AESTHETIC PANELSTHERMOSET AESTHETIC PANELSBig dimensionsClass A surfacesDimension stabilityCoupling controlStyle freedom

butbutRecycling problemsHeavy materials

Fiat Ulysse

Alfa Romeo Coupè

Dodge Viper Coupè

Ford Aeromax 9500

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Thermoplastic panels

THERMOPLASTIC AESTHETIC PANELSTHERMOPLASTIC AESTHETIC PANELSWeight reductionHigh style freedomEnvironmental friendlyPassive securityParts and functions integrationInvestments reductionMaintenance costs reduction

but ...but ...Dimensional stability problemsCritical coupling controlClass A surfaces difficult to obtain

Renault 5 GT turbo

Ecobasic

Smart

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TP or TS: which one is better?

There is not a definitive answer

Many factors influence the answerMany factors influence the answer

technical requirements:- cost target- weight vs. performance target- aesthetic aspect- performances

external boundary conditions

production rates

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Production rates

High production rates: between 500 and 1500/2000 cars/dayHigh production rates: between 500 and 1500/2000 cars/dayMost used production processes are:

sheet metal stampingpolymeric injection moulding

Niche vehicles: 50Niche vehicles: 50--100 vehicles/day100 vehicles/dayProduction processes currently tested are:

sheet metal hydroformingpolymeric non injection mouldingRTM/RRIM

Fiat Punto

Fiat Stilo

Fiat Barchetta

Fiat Coupè

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Why composites?

Composites (fibre reinforced polymer matrix materials)are applied on vehicles for:

function integration/pieces number reductionweight reductionstyle freedom...

Source: Bayer

Why do designers are thinking to use composites more and more?Why do designers are thinking to use composites more and more?Why cannot we continue to use stamped metal sheets?Why cannot we continue to use stamped metal sheets?

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GM Chevrolet Silverado

Integration

Pick-up rear box producedwith “RRIM/SRIM” technologyMaterial: PU reinforced with chopped fibreglassProcess developed in Italy by Cannon (for GM-USA)

Pick-up rear box producedwith SMC

Ford Explorer Sport Trac

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Weight reduction

Mercedes Class A tailgate

Aesthetic panelAesthetic panel: GEP Noryl GTX(PPE/PA)

Structure:Structure: GMTSMC

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BMW, carbon fibres panels

Concepts

GM Precept (2002), RRIM fascia,Kevlar FR roof panel , C FR bumper beams

DC Dodge ESX3 (2002), TP panels

DC CCV

Ford Equator (2002), Kevlar FR bumpers,fenders, wheel wells, lower trim panels

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Sport cars

GM Ultralite (1992), carbon SMC

Lamborghini Diablo GT, hand lay up carbon fibre

Mc Laren F1

Porche Carrera GT

DC Pronto Spider, PET panels

Mosler Automotive MT900, carbon fibre panels

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Current production

Ford Excursion,SMC trims

Ford Thunderbird 2002, all SMC panelsFord Th!nk, rotomoulded PE panels,ABS roof panel

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Cost/Part vs Production Number vs Production Method - 3sqm Body Component (Hood)

10

100

1.000

10.000

100.000

1.000.000

10 100 1000 10.000 100.000 1.000.000

No. Produced

£ C

ost/p

art

CBS in Carbon mould

PrePreg carbon in Carbon mould

CBS in Ni mould

Steel in Steel mould

RTM in Carbon mould

RTM in Ni mould

SMC in Steel mould

CBS (CompositeBody Structure) is aSP System registeredtrademark:a laminatedmaterial with sandwichstructure

Manufacturing costs

Source: SP System

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Composite process simulationSMC compression mouldingSMC compression moulding FEM model

The bumper

Initial charge

Melt flow

Alignment coeff.Alignment direction

Young modulusOrthotropic model

Structuralsimulation

Technalysis®Passage ® /Compression

if

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Vehicle history refers to metals, not to plastics!!!Vehicle history refers to metals, not to plastics!!!

Some external conditions (fuel consumption, weight reduction,higher performances, niche vehicles, ..) are pushing toward wideruse of composite materials, but ….

many designers do not still know composites each manufacturing process has its own best production rate/cost ratioyou need to find a manufacturer able to produce whatyou are asking him...

Conclusions

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...it is necessary to consider pros and cons for each applicationthe process strongly influences the final product

So ...…. you must…