HYBRID COMPOSITE DOOR BEAM FOR MASS PRODUCTION

Transcription

1 HYBRID COMPOSITE DOOR BEAM FOR MASS PRODUCTION Design, Analysis, Optimisation, Testing, Productionisation 2017 by Plasan 1

2 ABOUT MYSELF NIR KAHN Coventry University Transport Design Graduate Chief Designer of Plasan since 2001 Director of Design since by Plasan 2

3 CONTENTS 20 minute crash course About Plasan Predicting composite behaviour in crash Design architecture for mass production in composites Complying with requirements written for metals Door beam case study Summary & Questions 2017 by Plasan 3

4 ABOUT PLASAN World s leading designer and supplier of lightweight composite vehicle bodies >1000 composite vehicle bodies/month 2017 by Plasan 4

5 ABOUT PLASAN International company with R&D and manufacturing facilities in Israel, US, and France plus broader partner network 2017 by Plasan 5

6 ABOUT PLASAN CARBON COMPOSITES World s leading supplier of Class A carbon-fibre automotive parts CLASS A 40K CARS PER YEAR SRT Viper bonnet photo: SPE Automotive 2017 by Plasan 6

7 LEADING THE INDUSTRY Paradigm shift for the automotive industry 40K CARS PER YEAR 2017 by Plasan 2017 by Plasan 7

8 MASS PRODUCTION FACILITIES Grand Rapids, Michigan, USA Dedicated to mass producing composites for the automotive industry 2017 by Plasan 8

9 THE MODEL HIGH RATE DYNAMIC ANALYSIS AND TESTING BLAST TEST A mine blast is essentially the same as a crash impact, just from underneath Hybrid III dummies Simulation calibrated by physical testing 2017 by Plasan 9

10 CARBON COMPOSITES CRASH MODELING Velocity [m/s] Force [kn] Braking Forces N Displacement [1E-3m] Steady state forces N 2017 by Plasan 10

11 it s all essentially about absorbing and redirecting energy, about making a strong, safe, effective vehicle. It s an extreme version of what every car manufacturer on the planet is trying to do TOM FORD TOP GEAR MAGAZINE JULY 2016 when you combine it with Plasan s ideas for the use of materials and general production ethos, it will be vehicles like the Plasan SandCat that really revolutionise the car industry 2017 by Plasan by Plasan 11

12 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 2017 by Plasan 12

13 COST/KG SAVED 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 2017 by Plasan 13

14 THE FIRST PROPOSAL TO MAKE CARS FROM PRESSED STEEL But welds are ugly and how will we give it that beautiful wood texture that our customers expect? How can we get steel to splinter on impact like the regulations require? 2017 by Plasan 14

15 DESIGNING A MASS-PRODUCEABLE COST- EFFECTIVE COMPOSITE BIW Pultrusions Metal composites RTM Pressure Press 2017 by Plasan 15

16 ROOF CRUSH FMVSS 216 Local buckling: F = 8 40mm Global buckling: F = 9 60mm 2017 by Plasan 16

17 SIDE POLE IMPACT The frame absorbed the crash energy without penetration into the occupants volume 2017 by Plasan 17

18 STRUCTURAL COMPOSITE CHALLENGES Meeting standards written for metals Cracking Separation Durability Fatigue Paint Temperature Attachment 2017 by Plasan 18

19 BEAMS FIRST Holistic approach to composites is favourable To ease adoption of new pultrusion-based architectures Plasan is taking a Beams first approach with OEMs Bolt-on but structural, crash critical Prove design/analysis/test Prove produceability, processes, compatibility Challenging economic challenge to replace a cheap steel stamping Having made a case for this, the door is open to full BIW 2017 by Plasan 19

20 CASE STUDY DOOR BEAM Steel door beam = 1.5kg 2017 by Plasan 20

21 MODEL SET-UP FMVSS 214S Composite or steel beam Impactor (movement 457mm) Supports 2017 by Plasan 21

22 THREE-POINT BENDING DROP TEST Pure Carbon Fibre, standard lay-up, pultruded beam 2017 by Plasan 22

23 THREE-POINT BENDING DROP TEST Hybrid Composite, optimised lay-up, pultruded beam 2017 by Plasan 23

24 FATIGUE TESTING 2017 by Plasan 24

25 STEEL DOOR BEAM RESULTS Results of simulations Maximum force 16700N 2017 by Plasan 25

26 COMPOSITE TYPE 1 DOOR BEAM RESULTS Results of simulations Maximum force 30,000N 2017 by Plasan 26

27 COMPOSITE TYPE 2 DOOR BEAM RESULTS Results of simulations Maximum force 25,000N 2017 by Plasan 27

28 DOOR BEAMS FORCE COMPARISON Results of Simulation 2017 by Plasan 28

29 DOOR BEAMS ENERGY COMPARISON Results of Simulation 2017 by Plasan 29

30 DOOR BEAM RESULTS SUMMARY Design Material Mass, kg Energy, J Peak Force, kn 150mm Original Steel ,700 Composite 1 A ,000 Composite 2 B , by Plasan 30

31 COMPOSITE (DOOR BEAM) SUMMARY The main energy absorption mechanism in carbon fibre composites is based on brittle failure More extensive failure results in more effective energy absorption Hybrid composite beams allow maximum energy absorption without detachment Composite beams have better performance than steel beams Composite beams can reduce weight by % cost-effectively 2017 by Plasan 31

32 SUMMARY Composites can efficiently absorb energy לחץ כדי לערוך סגנון כותרת של תבנית בסיס Heavier and stressed parts have greater potential Design for composites Design for manufacture 2017 by Plasan 32

33 THANK YOU 2017 by Plasan 33