2015-12-1 imeche lightweighting_v2

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Innovations in Composite

Engineering & Light-weighting

Steve Fletcher - BEng (Hons) CEng MIMechE

Head of Engineering

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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

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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)

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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

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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.

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Lightweight Composites

From prototype to volume production

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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)

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Composite Enabling Technologies

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Design for Performance,

Manufacturing & Cost

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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

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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


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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


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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


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C-X75 Phase 1 Body Actual

BIW Weight: 160kg

BIW Torsion Mode: 75Hz

Torsional Stiffness: 56kNm/o

Bending Stiffness: 15kN/mm

Suspension Local k’s: 14-59kN/mm

Lamborghini Aventador

249.5kg (+56%)

44.9Hz (-40%)

35kNm/o (-38%)

Performance Benefits


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Manufacturing Processes:

Preform & Lay-up Automation


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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

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<10 min cycle time

Preforming

(Penso alternate method)

and Trim

Ply stack

(Penso alternate technology)

Trimming

(5-Axis CNC)

using alternate method

Advanced

demould


Press forming

(Hot Compression

Mould Press),

demould & set up

27 min 15 min 25 min 10 min 20 min

Preforming

(vacuum bladder)

and Trim

Laminating Trimming

(5-Axis CNC)

using manual fixings

Demould Press forming

(Hot Compression

Mould Press),

demould & set up

<10 min <10 min <10 min <10 min <10 min

INITIAL PROCESS

IMPROVED PROCESS

27 min cycle time


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10 min

cycle time


5. Demould


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Hot Compression Moulding

High Pressure Resin Transfer Moulding


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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


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Penso’s Lightweight Technology

State-of-the art hot

compression moulding

Cycle times <7

minutes

Press forming

10 registered patents suited to use in the

automotive, rail and aerospace industries

HP-RTM

State-of-the art high-

pressure resin transfer

moulding

Cycle times <5 minutes


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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


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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


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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.

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Steve Fletcher Head of Engineering

[email protected]

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:[email protected]

2015-12-1 imeche lightweighting_v2

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