Technology for Safe and Lightweight Automobiles

Transcription

1 AUTOMOTIVE Plastics Application Technology for Safe and Lightweight Automobiles Sudhakar R. Marur

2 Table of Contents Preface...xv Chapter 1 Introduction to Plastics Application Technology Introduction Application Development Cycle Voice of the Customer Benchmarking Material Selection Styling and Industrial Design Computer-Aided Design Computer-Aided Engineering Process Modeling Tooling Prototyping Secondary Operations Part Testing Material Selection Methodology Screening of Material Properties Conversion Processes Structural Requirements Environmental Conditions Assembly and Secondary Operations Cost Factors Regulations and Standards Compliance Advantages of Plastics Styling Freedom Material Property Performance Part Integration Weight Reduction System-Level Cost Reduction Key Automotive Plastics Applications Safety and Energy Management Interiors and Occupant Safety Glazing...11 vii 6351_Book.indb 7

3 1.5.4 Plastic-Metal Hybrid Structures Headlamps Body Panels Under-the-Hood Components Summary References...17 Chapter 2 Crash and Energy Management Systems Introduction Safety as an Emerging Global Concern Regulatory and New Car Assessment Program Crash Test Requirements Pedestrian Impact Tests Low-Speed Vehicle Damageability or Bumper Structural Tests High-Speed Crashes for Occupant Protection Impact and Energy-Absorption Efficiency Design of Energy-Absorbing Elements Pedestrian Protection Vehicle Bumper Stiffness Profile Design of Pedestrian-Safe Bumper Systems Pedestrian Energy Absorbers Pedestrian Energy Absorbers Middle Load Path SUV Energy Absorbers Upper Load Path Undertray Lower Load Path Countermeasures for Low-Speed Vehicle Damageability Tests Bumper Design Challenges Thermoplastic Solitary Beam Solutions Hybrid Plastic-Metal Bumper Beam Solutions Low-Speed Damageability and Lower-Leg Impact-Compliant Bumper System Conflicting Energy-Absorbing Requirements for Bumpers Dual-Stage Energy-Absorber Approach Performance Evaluation Vehicle Structural Integrity for High-Speed Crashes Hybrid Rail Extensions for Frontal Crashes...67 viii 6351_Book.indb 8

4 2.9.2 Plastic Reinforced Body-in-White Structures A Case Study on Roof Crush Countermeasures Summary Trends References...80 Chapter 3 Interiors Introduction Instrument Panel Key Drivers in Instrument Panel Design Automotive Instrument Panel Carriers Occupant Safety: Head and Knee Impact Processing Challenges of Instrument Panel Carriers Mold-Filling Simulations of Instrument Panel Carriers Seamless Airbag Design Tear Seam Plaque Study Knee Bolster Center Console Steering Wheel Introduction Metal versus Plastic Design Technology Materials Performance Requirements Role of Predictive Engineering Prototyping and Testing Interior Components Roof Energy Absorber Door Handle and Door Pull Cup Speaker Grille Cover Summary Trends References Chapter 4 Glazing Applications Automotive Glazing Overview Automotive Glazing and Global Regulations ix 6351_Book.indb 9

5 4.3 Automotive Glazing Role of Polycarbonate Weight Reduction Styling and Design Freedom Characteristics of a Glazing System Structural Performance Design for Structural Stiffness Role of Restraints Role of Curvature Role of Thickness Importance of Adhesive and Its Characterization Adhesive Testing Uniaxial Tension Dimensional Stability Effect of the Coefficient of Thermal Expansion Simulations and Experiments Design of Experiments Approach Acoustic Performance Transmission Loss Transmission Loss Spectrum: Glass versus Polycarbonate Sound Transmission Loss Performance Thermal Management Thermal Modeling of Semitransparent Materials: Spectral Transmission and Absorption HVAC Load Advantages of Polycarbonate Improved Performance of Electric Vehicles Soak Performance of Polycarbonate Glazing Conversion Process Two-Shot Injection Compression Molding First-Shot Injection Compression Molding Sequential Injection Compression Molding Simultaneous Injection Compression Molding Breathing Injection Compression Molding Second-Shot Injection Overmolding Process Prediction Methodology of Two-Shot Injection Compression Molding Process Part and Tool Development Filling Correlation Warpage Methodology Development x 6351_Book.indb 10

6 Measurement Setup Approach Summary Trends References Chapter 5 Plastic-Metal Hybrid (PMH) Structures Introduction Why Hybrid Designs? Types of Hybrids Overmolding Adhesive Bonding Collar Joining Polymer Injection Forming Direct Metal Deposition Mechanical Fasteners Heat Staking Reinforcing Structure Closed-Channel Hybrid Structures Open-Channel Hybrid Structures Processing of Hybrids Processing of Closed-Channel Hybrid Structures Processing of Open-Channel Hybrid Structures Mold Design Performance of Hybrid Structures Application of Plastic-Metal Hybrids Front-End Module Application Development Design Methodology Performance Evaluation Summary Trends References Chapter 6 Headlamp Applications Automotive Lighting Overview Automotive Lighting Global Regulations Automotive Lighting Role of Thermoplastics Headlamp Reflectors Material Replacement xi 6351_Book.indb 11

7 6.4.2 Thermal Management Structural Performance Beam Pattern and Optical Performance Stress-Free Reflector through Reflector Bracket Tooling and Processing Gate Design Venting Tool Thermal Management Tool Surface Treatment Processing Headlamp Bezels Headlamp Lenses Headlamp Assembly Pedestrian Safety Summary Trends References Chapter 7 Body Panels Introduction Functional Requirements for Body Panels Material Selection in Engineering Thermoplastics Body Panels Fenders Manufacturing Considerations in Fender Design Design for Paintability Material Characterization and Material Model for Fender Predictive Studies Case Study of Finite Element Analysis to Optimize Support Configuration Fender Impact Resistance Design and Development of the Thermoplastic Tailgates Functional Requirements of Thermoplastic Tailgates Tailgate Impact Resistance and Structural Rigidity Tank Flap Spoiler Summary Trends References xii 6351_Book.indb 12

8 Chapter 8 Under-the-Hood Applications Introduction Material Requirements for Under-the-Hood Applications Heat Aging Chemical Resistance Types of Engineering Plastics in Under-the- Hood Applications Under-the-Hood Application Examples Oil Pans Wire Coating Engine Cover Fuel Lines Designing of Under-the-Hood Components Turbo Air Duct Design Validation Throttle Body Types of Throttle Body Materials for the Throttle Body Predictive Tools to Drive Thermoplastics Usage in Electronic Throttle Body Processing of Throttle Body Current Status of Thermoplastics in Electronic Throttle Body Summary Trends Material Advancements Processing Advancements Secondary Process Advancements Design Trends Green Trends References Chapter 9 Sustainability in the Automotive Industry Introduction Sustainability Trends in the Automotive Industry Lightweighting and Fuel Efficiency Materials for Lightweighting xiii 6351_Book.indb 13

9 9.2.2 Quantifying Environmental Benefits of Lightweighting through Life Cycle Assessment Life Cycle Assessment Case Studies for Lightweight Materials The Future of Lightweighting with Plastics Design for Sustainability Renewable-Sourced or Bio-Based Materials for the Automotive Industry Why Renewable Resources? Carbon Footprint of Bio-Based Raw Materials Bio-Based Materials for Plastics Cellulosic Plant Fibers Bio-Based Polymers Made from Monomers or Intermediates from Renewable Resources Highly Biodegradable Polymers from Renewable Resources Limitations of Sourcing Raw Materials from Renewable Resources to Make Polymers Emerging Bio-Based Raw Materials Bio-Based Plastics for the Future Automotive Industry End-of-Life Scenarios Recycling in the Automotive Industry End-of-Life Options for Selected Polymer Families Challenges and Limitations to Plastics Recycling Effect of Recycling on Carbon Footprint Reduction Reuse End-of-Life Scenario for the Future Summary Trends References Abbreviations Index About the Editor Contributors xiv 6351_Book.indb 14

10 Plastics Application Technology for Safe and Lightweight Automobiles Sudhakar R. Marur This book focuses on using plastics in automobiles for traditional applications such as interiors and body panels, and for more advanced applications such as glazing and under-the-hood components. It provides application technology development for various aspects of automotive design concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making. It is based on a decade of research and real-world application of the authors. Described are design and manufacturing aspects of energy absorbers, fenders, front-end modules, instrument panels, steering wheels, headlamp assemblies, throttle bodies, glazing, and tailgates, as well as exterior components such as roof racks, wipers, door handles, and rearview mirror assemblies. Using engineering thermoplastics for such applications will improve safety and reduce the weight of next-generation automobiles. Readers will gain an understanding of design and manufacturing methodologies of plastics and the means to apply them to a particular vehicle platform. The intent is to help further engineering expertise about using plastics in automobiles so that they can be safer, lighter, and more energy efficient. About the Editor Sudhakar R. Marur led the plastics application technology laboratory, as its technical director, for SABIC Innovative Plastics in Bangalore, India. Under his leadership, the team developed plastics application solutions for automotive companies worldwide. He has more than 23 years of experience in industrial R&D. He earned his PhD from the Indian Institute of Technology (IIT), Bombay, specializing in computational nonlinear structural dynamics, and did his postdoctoral research on nonlinear vibrations and elementology at National Aerospace Laboratories. R-415