2015-12-1 imeche lightweighting_v2

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  • 1

    Innovations in Composite

    Engineering & Light-weighting

    Steve Fletcher - BEng (Hons) CEng MIMechE

    Head of Engineering

  • 2

    Company Overview

    Consulting

    Composite

    Technologies

    Project Management

    Body Engineering

    FEA Simulation / Crash

    Light weighting

    EV Design

    High Volume Composites

    Cost Effective

    Tooling & Machining

    Integrated Composite Systems

    Trim Development

    Electrics & Electronics

    Prototype build

    Niche System Production

    Series Production

    Special Operations

  • 3

    Company Overview

    ENGINEERING CENTRE

    Coventry, UK

    ENGINEERING OFFICE

    London, UK

    Pune, India

    Accreditation

    TS16949 : 2009

    ISO9001 : 2008

    Core Competencies

    Consulting

    Composite Technologies

    Special Operations

    Clients

    Strategic Alliances

    Cytec (Oct 2015)

    Pricol Technologies (Jan 2015)

  • 4

    History

    2005

    Management

    buy out of P+Z,

    Rebranded

    Penso

    Consulting

    2006

    Complete

    interior design,

    manufacture &

    production

    supply Brink

    Carver One

    2007

    Fiat Professional

    Specialist turnkey

    vehicle programme

    engineer and

    manufacture taxis

    for UK public hire

    sector

    2008

    Engineer and

    manufacture

    London Specific

    Vito Taxi for

    Mercedes Benz -

    Full European Type

    2 approval and

    homologation

    2009

    Spyker C8 Aileron

    complete vehicle

    engineering,

    interior trim and

    convertible roof

    system for Spyker

    derivative.

    2010

    ISO9001 and

    TS16949

    accreditation

    2011

    Tier-1 supplier into JLR L538C Evoque Convertible

    L405 LWB

    CX75 engineering &

    Composite Body

    Structures

    X152X Prototype, Tonneau

    ETO engineering support.

    Project Donington

    engineering and build.

    VARCITY Megacity.

    2012

    Supply of Production,

    Interior Trim for

    Morgan 3 Wheeler

    2013

    Re-Accreditation

    of ISO9001 and

    TS16949

    Support Product

    Launch L405 LWB

    2014

    L538C

    L538C ADV

    CDRM Models

    P231

    SP1 L322

    SP2 L405

    X261

    SP = Special Project

    2015

    Bimini Hood

    X590

    X760 LCN

    CF Train Door

  • 5

    Company Growth

    Turnover

    Penso has grown rapidly over last few

    years diverse customer base.

    Turnover tripled over last 5 years

    Forecast for 2015: 32m

    Growth supported by renaissance in UK

    based Manufacturing.

    UK Government Support

    National (Innovate UK)

    Local (City Council)

    Legislation is driving need for lower

    emission vehicles.

  • 6

    Lightweight Composites

    From prototype to volume production

  • 7

    Lightweight Composite Technology

    EU CO2 Legislation as Technology Driver

    Average UK new car CO2 emissions & EU

    new car CO2 regulation targets

    2020: 95g/km (legislation)

    2025: 75g/km (under review)

  • 8

    Composite Enabling Technologies

  • 9

    Composite Enabling Technologies

    Design for Performance,

    Manufacturing & Cost

  • 10

    Process flow developed over the last 5

    years on multiple composite

    engineering programmes

    Concept Engineering

    - Primary joint and beam stiffness and

    strength calculated.

    Detail Design Engineering

    - Full ply stack definition and

    optimisation

    Manufacturing Engineering

    - Producibility assessments

    - Cuts & Darts

    - Automated Ply-Book generation and

    digital data output

    State of the Art Design & Simulation Tools & Processes

    Design for Performance, Manufacturing & Cost

  • 11

    Advanced Simulation Tools

    - Crashworthiness

    - NVH

    - Durability

    - Optimisation

    State of the art materials modelling

    methods

    - Penso materials modelling methods

    developed from existing ASTM

    methods to align with latest technology

    requirements

    Advanced toolset allows detailed

    analysis of joints and ply stacks

    Simulation Methods for Composites

    Design for Performance, Manufacturing & Cost

  • 12

    Advanced simulation technologies applied

    Material card data developed to enable predictive

    methods.

    - Tests are developed variants of ASTM standard

    methods.

    Composites Crashworthiness Simulation

    C-X75 30FFB Crash C-X75 30FFB Crash

    Penso Material

    Development Process

    Design for Performance, Manufacturing & Cost

  • 13

    Optimisation setup Optimisation - Initial

    Laminate Optimisation

    Continuous phase - 1 Continuous phase - 2 Continuous phase - 3 Continuous phase - 4 Continuous phase - 5 Continuous phase - 6 Continuous phase - 7 Continuous phase - 8 Continuous phase - 9 Continuous phase - 10 Continuous phase - 11 Continuous phase - 12 Continuous phase - final Optimisation Discrete phase Rationalise Optimisation

    results

    Design/manufacture requirements Manual optimisation

    Local reinforcement for

    attachment points

    Final layup

    C-X75 Tub

    Includes Penso developed algorithms to optimise for Material & Process

    costs in parallel with mechanical performance and weight

    Optimisation

    Triangle

    Weight

    Performance

    Cost

    Design for Performance, Manufacturing & Cost

  • 14

    C-X75 Phase 1 Body Actual

    BIW Weight: 160kg

    BIW Torsion Mode: 75Hz

    Torsional Stiffness: 56kNm/o

    Bending Stiffness: 15kN/mm

    Suspension Local ks: 14-59kN/mm

    Lamborghini Aventador

    249.5kg (+56%)

    44.9Hz (-40%)

    35kNm/o (-38%)

    Performance Benefits

    Design for Performance, Manufacturing & Cost

  • 15

    Manufacturing Processes:

    Preform & Lay-up Automation

    Composite Enabling Technologies

  • 16

    1. Raw material

    defrost 2. Nesting and

    kit cutting of parts

    (Pattern cutting)

    4. Preforming

    and Trim 3. Ply stack

    7. Trimming

    (5-Axis CNC) 5. Advanced

    demould

    6. Press forming

    (Hot Compression

    Mould Press)

    demould & set up

    8. Sample

    Inspection

    PPCP Process Development

  • 17

  • 18

    10 min

    cycle time

    PPCP Process Development

    5. Demould

    (Penso alternate method)

  • 19

    Hot Compression Moulding

    High Pressure Resin Transfer Moulding

    Composite Enabling Technologies

  • 20

    Hot Compression Moulding & High Pressure Resin Transfer Moulding

    High tonnage press facilities with

    large platen formats, allowing the

    production of large integrated

    components.

    High pressure RTM equipment

    automatically linked to specific

    presses.

    Ultrasound NDT Equipment for panel

    inspection. (Lamination

    characteristics, bonding

    characteristics)

    Inspection Booth

    Composite Enabling Technologies

  • 21

    Pensos Lightweight Technology

    State-of-the art hot

    compression moulding

    Cycle times

  • 22

    Simultaneous Tooling Development

    Substantial Research and

    Development into manufacturing

    processes for high volume CFRP

    production, simultaneously aligned

    with tooling development to suit

    product performance and cost

    requirements.

    Tooling in aluminium

    Low volume production using

    aluminium tools

    High volume production using steel

    tooling

    Composite Enabling Technologies

  • 23

    Simultaneous Tooling Development

    Substantial Research and

    Development into manufacturing

    processes for high volume CFRP

    production, simultaneously aligned

    with tooling development to suit

    product performance and cost

    requirements.

    Tooling in aluminium

    Low volume production using

    aluminium tools

    High volume production using steel

    tooling

    Composite Enabling Technologies

  • 24

    Further Development & Growth

    Penso next investment

    Composites press facility expansion

    with semi-automated and fully

    automated press lines.

    Fully automated BIB assembly

    facility

    Tool Room expansion for increased

    capacity requirements

    Full turnkey composites facility from

    product engineering through to

    volume production supply.

  • 25

    Steve Fletcher Head of Engineering

    steve.fletcher@penso.co.uk

    M: +44 (0)7508 225 762

    Penso Consulting Ltd

    Woodhams Road

    Coventry

    Warwickshire

    CV3 4FX

    United Kingdom

    T: +44 (0)2476 217760

    www.penso.uk.com

    www.linkedin.com/company/penso

    www.twitter.com/PensoGroup

    mailto:steve.fletcher@penso.co.uk