technology trends in lightweight design for the...

© Fraunhofer ICT

Technology Trends in Lightweight Design for the Transportation Industry

Fraunhofer ICT – KIT FAST & IAM-WK – Fraunhofer Project Centers FPC

Peter the Great, St. Petersburg, Polytechnic UniversityNovember 21st, 2016

© Fraunhofer ICT

Applied research is core of all activities pursued by the Fraunhofer-Gesellschaft.

Founded in 1949, the research organization undertakes applied research that drives economic development and serves the wider benefit of society.

Its services are solicited by customers and contractual partners in industry, the service sector and public administration.

IntroductionFraunhofer Gesellschaft

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Founded in 1949 in Munich

66 institutes and research units in

Germany

More than 24,000 employees

Annual budget is about € 2,2 billion,

partly public founded

Representative offices, research units,

and subsidiaries worldwide

The Fraunhofer-GesellschaftMain locations of the Fraunhofer institutes and research institutions in Germany

Main sites

Other sites

Fraunhofer ICTPfinztal

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Organization chart of the Fraunhofer ICT

Energetic Materials

Dr. H. KrauseDr. T. KeicherDr. S. Löbbecke

EnergeticSystems

W. EcklG. LangerDr. J. Neutz

Applied Electrochemistry

Dr. J. TübkeDr. K. Pinkwart

Environmental Engineering

R. SchweppeS. Rühle

Polymer Engineering

Prof. Dr. F. HenningDr. J. DiemertDr. T. Huber

Administration

Dr. B. Hefer, C. Steuerwald

General Management

Dr. S. Tröster

Institute Director

Prof. Dr. P. Elsner

Deputy Directors

Dr. H. Krause, Prof. Dr. F. Henning

Controlling

C. Steuerwald

Project Group for Sustainable MobilityFH Braunschweig-Wolfenbüttel, WolfsburgDr. J. Tübke

Project Group for New Drive Systems NAS, KarlsruheDr. H.-P. Kollmeier, Prof. Dr. P. Elsner, Prof. Dr. P. Gumbsch (IWM)

Fraunhofer Project Center FPC UNIST (Ulsan, Korea)Prof. Dr. F. Henning, Prof. Young-Bin Park

Fraunhofer Project Center FPC London (Ontario, Canada)Prof. Dr. F. Henning, V. Ugresic

Fraunhofer ICT-IMM, MainzProf. Dr. Michael Maskos

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National and International NetworkExtended Research Activities

Access to key markets

R&D network

Student exchanges

Graduate schools

FPC@UNISTFPC@Western

USA &Canada

Europe

Asia

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Railed vehicles: aluminum is the dominating material, however HSS shows a

growth of 14 %

25.11.2016

Market for railed vehicles sectorMarket volumein bn €

MMC

FRP

Aluminium

Steel (high strength)

Plastics

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Shipping sector shows small growth due to expansion of aluminum market (4 %).

25.11.2016

Market volumein bn €

FRP

Aluminium

Plastics

Market for shipping sectorMarket for shipping sector

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Main lightweight-materials for the aerospace sector are aluminum (1,7 % growth),

titanium (13% growth) and composites (15 %). Magnesium might also become

important in the future (30 %).

25.11.2016

Market volumein bn €

MMC

FRP

Titan

Magnesium

Aluminium

Plastics

Market for aerospace sector

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Weight Reduction of Airplanes

Source: Prof. Dr.-Ing. Klaus Drechsler

© Fraunhofer ICT

University Paderborn/ Tröster

50

100

150

0,15 0,3 0,45W

eig

htre

du

ction

[kg

]

Reduction of fuel consumption [l/100 km]

Reduction of CO2-Emissions [g CO2/km]

8,54,3 12,8

BMW 7er

VW Golf

VW 1- Literauto

VW Lupo

Opel Corsa

Opel Omega

Increase of vehicle mass within 50 years

Year

Weig

ht

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The transportation sector, in particular the automotive sector as driving force, is the

most important market for lightweight-technologies regarding market volume.

Strong growth of other markets (e.g. wind energy with ~10 % size of the volume of the

transport market) is not likely to take place before 2020.

25.11.2016

Transportation market [BCC 2013] in bn €

Shipping

railed vehicles

Aerospace

Automotive

Buses and trucks

Wind energy

Wind energy (GFRP + CFRP )

© Fraunhofer ICT 13

The dimension of the entire global lightweight market will be in the order of the

dimension of the market for automotive applications. Studies are assuming a

growth of about 7-8%.

25.11.2016

Lightweight market automotive -comparison of different studies (in bn €)

BCC 2013: Automotive (without buses and trucks)

BCC 2013: Automotive (total)

MacKinsey 2012: Automotive (total)

Frost & Sullivan 2011: Automotive (passenger vehicle)

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Forel Study - Accepted Costs for Lightweight Design

1425.11.2016

Source: Forel Studie -2015

automotive sector

with conventional engine

automotive sector

with electric drive

aerospace

aerospace – outer space

up to 7

up to 18

up to 500

up to 3000

© Fraunhofer ICT

Lightweight design is mainly established in the transportation sector.

Automotive industry is most important; Utility vehicles (buses and trucks) show strong growth

Other markets, e.g. wind energy, nowadays of lower importance but with a strongly

increasing tendency emerging markets

Lightweight design based on metals is and will be the main market in automotive until

approx. 2020

High-strength-steel shows highest growth rate in automotive; Magnesium shows growth rate as

well but based on a much lower market size emerging market

Plastics show constant but intermediate growth rate

Composites show very high growth rate and will most likely be of increased importance

in the long term (2020 and later) cost as main challenge

In the long term increasing trend towards hybrid lightweight design

Conclusion Market Trends Analysis

1525.11.2016

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Steel/metal design

FRP

MMP Approach

Source: Audi, Porsche

Opportunities&

New Challenges

New materials

Further development of methods ,

materials and processes to access

opportunities for automotive industry

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MMP Approach

Component performance Economics

A R E A S O F I N T E R A C T I O N

QUALITY

TIME

COSTS

PROCESSES

METHODS

MATERIALSS Y S T E M E F F I C I E N T

L I G H T W E I G H T D E S I G N

MMP-Approach

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Methods - Materials - Processes

Virtual Simulation Chain

Initial analysis of component manufacturability

Linkage of process simulation and structure simulation

Integration of production boundary conditions and updated material properties into structure simulation

Requirements for Multi-Material-Design

V I R T U A L S I M U L A T I O N C H A I N

F L O W O F I N F O R M A T I O N

O P T I M I Z A T I O N

Geometry Forming Curing /

cooling

Part Assembly

integral

construction

differential

construction

Vehicle

conceptVehicle

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KIT Institute of Vehicle System Technology –Lightweight technology FAST

Process simulation

Optimization of cycle times for manufacturing of composite components

Evaluation and improvement of process control and machinery

Dissemination of relevant material and process information on structural simulation (within the context of CAE-chain, e.g. fiber orientation, fiber volume content, porosity)

Structural simulation

Simulation of deformation and failure behavior of composite structures

Investigation of the influence of manufacturing effects on the component behavior

Consideration of production factors to increase the prediction accuracy (integration in the CAE-chain)

Further development of models and methods for hybridization

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Material modification

Chemical (molecular structure, cross-linking, cristallinity…)

Physical (reinforcements, additives, fillers, …)

Tailored materials

Material analysis

Mechanical testing

Thermal analysis

Chemical analysis

Morphological characterization

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KIT Institute of Applied Materials –Materials Science and Engineering IAM-WK

Polymer Technology

Design of polymer materials

Polymer processing

Hybrid and Lightweight Materials

Mechanical Characterization of polymer and metal based composites under near-service loads

Microstructural analysis of composites usingX-ray computed tomography

Development of in-situ-test methods for the analysis of damage in composites

1 m

m in

thro

ug

h-

thic

kn

ess d

irectio

n C

Visualization of in-plane orientation 1200 x 750 x 400 Voxel

B

A

B

3.5

m

m

CFRP

Insert

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Thermoplastic process ing

Thermoset process ing

High-performance composites

Preforming technologies Injection technologies (EP, PU, Cast-PA) Process and structural simulation Manufacturing in industrial scale (3600t, 640t)

D-SMCSheet Molding Compounds (SMC) PU-fiber spraying

Tape placement LFT – injection molding LFT – compression moldingHandling technologies


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Fraunhofer ICT - Department Polymer Engineering

Compounding and extrusionMaterials and cutting-edge processing technology

NanocompositesFunctional composites and their characterization

Foam technologiesProcesses and materials for particle and extrusion foams

Thermoplastic processingInjection and compression molding, thermoplastic composites

Thermoset processingProcess and material development, tailored SMC

High-performance compositesRTM processing chain, injection, preforming, prepregs

Microwaves and plasmasMicrowave technology, surface modifications

Plastics testingMechanical and rheological analysis, microscopy, DoE

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Braiding*1

Overview of process technologies

*1Continuous-fiber preform

Braiding*1

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Thermoplastic composites-

Discontinuous fiber reinforcement

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Overview of Process Technologies

Thermoplastic processing

Unreinforced thermoplastics

Thermoplastic foam injection molding

Processing of functionalized polymers (e.g. electrically-conductive compounds)

Advanced processing technologies for injection molding

Discontinuous-fiber reinforced thermoplastics

Direct processing of long-fiber reinforced thermoplastics (LFT-D) in compression and injection molding (CM / IM)

Foaming technologies for fiber reinforcedthermoplastics

Continuous-fiber reinforced thermoplastics (CFRTP)

Automated thermoplastic tape-laying

Local reinforcement of discontinuous-fiber reinforced thermoplastics to create function-integrated designs

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Discontinuous-fiber reinforced thermoplastics Typical applications of LFT

Thermoplastic composites with discontinuous-fiber reinforcement are already a well-established engineering material for semi-structural applications with constant growing market share

Frontend-module Golf VII; PA6/LGF

Source: BASF/VW

Seat structure BMW I3;PA6/LGF

Source: BASF/BMW

Instrument panel Ford Escape/Kuga; PP/LGF

Source: Faurecia/Sabic

Oil tray Actros;PA6.6/GF35

Source: Lanxess/Daimler

Gear carrier BMW 5er GT; PA6/GF

Source: ContiTech/BASF

Under body shield;PP/GF

Source: Polytec/VW

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Discontinuous-fiber reinforced thermoplastics CAE-Chain – Design and Concept

CAE-Chain for long fiber reinforced polymers (LFRPs)

Integrate design, process simulation and structure simulation

Allow systematic and efficient communication in between different software

Main goal is to create a more efficient product development method

V I R T U A L S I M U L A T I O N C H A I N



Process AssemblyPartGeometry

Topology/Topography

Mapping

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Discontinuous-fiber reinforced thermoplastics Processing technologies

Compression Molding (CM)

Processing of glass-mat reinforcedthermoplastics (GMT)

Direct processing of long-fiber reinforced thermoplastics (LFT-D-CM)

Injection Molding (IM)

Processing of short or long-fiber reinforced thermoplastics (SFT / LFT-IM)

Direct processing of long-fiber reinforced thermoplastics (LFT-D-IM)

Foaming technologies for fiber reinforcedthermoplastics (e.g. MuCell® , LFT-D foam,CBA -Chemical blowing agents)

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Discontinuous-fiber reinforced thermoplastics Principle of direct compounding of LFT in compression molding (LFT-D-CM)

LFT plastificate(open transfer)

Inline Compounder Natural

…

Reinforcing fibers :

Carbon

Glass

Matrix res ins :

Commodity Thermoplastics

Engineering Thermoplastics

Blends

…

Further developments in LFT-D-CM

Use of technical thermoplastics as matrix material (e.g. PPS, PEEK…)

Combination with continuous-fiber reinforcements

Compression molding

Mixing Extruder with die

Polymer + Additives

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Discontinuous-fiber reinforced thermoplastics Principle of direct compounding of LFT in injection molding (LFT-D-IM)

Matrix res ins :

Commodity, engineering and high temperature thermoplastics

Further developments in LFT-D-IM

Combination with continuous-fiber reinforcements

FIM – Foam injection molding (LFT-D Foam)

Twin screw extruder

Polymer + Additives

Injection unit

Melt buffer

Clamping unit

Natural

…

Reinforcing fibers :

Carbon

Glass

© Fraunhofer ICT

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Discontinuous-fiber reinforced thermoplasticsFunctional principle: integral foam structure

1 cm 1 mm

profile of a human humerus (left) [source: www.britannica.com]cross section of a PP-LGF30 injection molded integral foam component (right)

Kompakte Außenhaut

Schaumkern

Kompakte Außenhaut

300 µm

sandwich-like integral foam structure with a foamed core and a compact skinPP-LGF30

compact skin

compact skin

foamed core

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Discontinuous-fiber reinforced thermoplasticsFoam injection molding (FIM) – Fiber-reinforced integral foams

PP integral foam PP-LGF30 integral foam local density / stiffness I-beam / sandwich

po

sition in

cro

ss-s

ectio

n

300 µm300 µm 100 µm100 µm

PP-LGF30 integral foam fiber-reinforced cell walls fine-celled foam

© Fraunhofer ICT

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Discontinuous-fiber reinforced thermoplasticsLFT-Foams – Lightweight potential of the Breathing mold

CBAMuCell

LFT-D-Foam

increasing• wall thickness• density reduction• bending stiffness

delay timemold breathing

0,0

1,0

2,0

3,0

3,5 4,0 4,5 5,0 5,5 6,0

rela

tive

bendin

g s

tiff

ness

[ ]

wall thickness [mm]

PP-LGF30 CBA

PP-LGF30 MuCell

PP-LGF30 LFT-D

SB = EB ∙ Iy = EB ∙b∙h3

12

stronglyincreasing

slightlydecreasing

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Thermoplastic composites-

Continuous fiber reinforcement

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Continuous-fiber reinforced thermoplasticsTypes of continuous-fiber reinforcement

Benefits of continuous-fiber reinforcement

Semi-finished products containing fiber volume contents of up to 60 -70 %

High mass-specific part properties achievable

Part designs can be optimized for specific load cases

More stable mechanical performance at elevated temperatures

Increased dimensional stability

Reduced creep tendency (if loads are transferred into continuous fibers)

Application of thermoplastics in structural applications

UD-Tapes Wound Structures FabricsUD-Strands Profiles

source: Bond Laminatessource: Fiberforgesource: Zoltek source: Xperion

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Tailored Fiber Placement - TFP

FIBERFORGE® TFP System

UD Fiber Tape Tailored Blank Consolidated

Blank

Thermoformed

Part

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Continuous-fiber reinforced thermoplasticsThermoplastic tape-laying based on RELAY® technology

Advantages

Any fiber orientation possible

Varying thickness within a part possible

Minimized scrap

Recyclable material

Hybrid layup configurations possible

Automated process with short cycle times

Combination with other thermoplastic processing and joining technologies

Technical challenge

Limited drapeability and flowability

Economic challenge

The cost targets are often difficult to achieve in large series

ultrasonic welding

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Continuous-fiber reinforced thermoplasticsDifferences between tape-laying and semi-finished woven fabrics

No fiber ondulation(max. performance)

Reduced cutting scrap

No limitation on the fiber orientation 0 ° / 90 °

Gradual thickness changespossible

Source: Script of Paolo Ermanni (woven fabric) and www.hedag-recycling.de (tape layup)

.

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplastics CAE-Chain – Design and Concept

Main focus: Virtual Representation of the Continuous Virtual Process Chain

virtually combine design, manufacturing and structural validation

Requirements for Multi-Material-Design

V I R T U A L P R O C E S S C H A I N



Molding Cooling Part Assembly

integral constructiondifferential construction

Geometry Forming

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplastics Processing technologies

Automated thermoplastic tape-laying of tailored blanks

Thermoforming of fabrics and laminates

Alternative heating and consolidation methods

Investigation of process-controlled drapeability

Prediction and evaluation of process-inducedshape deformations (spring-in & warpage)

Hybrid thermoplastic composites with embedded continuous-fiber reinforcements in CM and IM

Function-integrated solutions for structural components

Local continuous-fiber reinforcements using wound structures or tailored blanks

Sandwich structures

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Fiberforge 4.0 – Machine Architecture

42

Spool Unwinding

Cutter

24 US-Welders Lay-up beam

Motion Table

Tape Tensioning

Tape Toogle

Rotation Axis

X- Axis

© Fraunhofer ICT

Fiberforge 4.0 - Improvements

43

Productivity

Fiberforge 4.0 is 3.5 times faster than Fiberforge Relay 2000

Continuous tape supply to lay-up system – no downtime due to reloading of spools

Cycle time of less than 1s per tape at maximum tape length of 2000mm;

including spot welding

Two shorter tapes (e.g. 300mm + 500mm) can be placed in a row

with same cycle time of less than 1s

Performance example

Glass fiber tapes (PP/GF60), with 0,25mm thickness + 165mm width +

average tape length of 1500mm results in a production capacity of 368 kg/h

Carbon fiber tapes (PA/CF55), with 0,16mm thickness + 165mm width +

average tape length of 1500mm results in a production capacity of 208 kg/h

© Fraunhofer ICT


44

Flexibility

Can work with all different formulations of thermoplastic tape

Range of tape width: max. 165mm; min. 50mm

Range of tape length: max. 2000mm; min. 30mm

Range of thickness: max. 0.4mm, min. 0.1mm

Up to 4 different tapes can be used within a production run

Tape source can be switched from one tape to the next

With the capability to lay-up more than one tape in a row at one cycle, more than one

individual part at a cycle can be produced, with a significant cycle time advantage

RH partMotion Table

LH part

© Fraunhofer ICT


45

Efficiency

New angle cutting system does minimize the waste of material

Angle cutting without any cycle time reduction

Loss of material w/o angle cut = 5% minimized with angle cut = 2,5%

Gap between the tapes can be set from -2 to +5mm (overlap)

Lay-up with small gap; e.g. 0,4mm Lay-up with overlap; e.g. 3mm

Low level of complexity due to 2D lay-up – small effort to generate machine program

© Fraunhofer ICT

46

Precision

High accuracy and repeatability

Constant gap between the tapes within a layup

Machine repeatability: C = 0.01°; Y = 0.25 mm; U = 2.0 mm (U is the tape feed axis)

Machine resolution: C = 0.005°; X, Y = 0.03 mm; U = 0.1 mm

Fiberforge 4.0 – Improvements / Applications

Applications

- Seat structures - Load Compartment

- Battery compartment - Floor pan

- Door inner - Hood, roof and tail-gate structural reinforcement

- Bumper beam - Fire wall

- Local reinforced front end carrier and underbody shielding

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsDevelopment of consolidation process technologies

Consolidation Process- based on hydraulic presses (HTP)- based on vacuum technology

(fast out-of-autoclave process)

Tailored-blank(Consolidated)

Composite PartTailored-blankUD Tape

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsHeating-Transfer-Pressing (HTP) consolidation process

Metal caul sheets

Layup made from UD-tapes

Unconsolidatedtape layup

Contact heating to processingtemperature and pre-consolidation

Solidification - Coolingwith applied press force

Monolithiclaminate

© Fraunhofer ICT

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Process characteristics

Low invest

No consumables

Closed-loop process

Exclusion of oxygen(minimization of thermal degradation)

Pressure > 1 bar out of autoclave achievable Area of vacuum (A1) > Area of tape layup (A2)

Short cycle times (< 60 sec)

High surface quality

Low fiber distortion

SealingVacuum sewer

Tape layupIR-transparent

tool wall

A1 A2

Continuous-fiber reinforced thermoplasticsRadiation-induced vacuum consolidation

© Fraunhofer ICT

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C-Scan CT

Po

or

Qu

ali

tyG

oo

dQ

ua

lity

SEM

Mechanical analysis

Optical analysis

Continuous-fiber reinforced thermoplasticsAnalysis of consolidation quality

Execution AnalysisDefinition

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsLaminate forming in context of the MMP approach

M E T H O D S

Process realization

Process characterization

Process monitoring

P R O C E S S E S M A T E R I A L S

Process Simulation

Model development

Part validation

Customized testing set ups

CAE chain approach

Mechanical & morphological characterization- data interpretation- link to M & P

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplastics Draping behavior of tape laminates

Process analysis and evaluation duringnon-isothermal stamp forming

Temperature profile characterization

Evaluation of wrinkling formation

Deformation state analysis

Characterization of material propertiesrelevant for forming simulations

Friction (ply-ply & tool-ply)

In-plane shear

Single-ply bending

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PPS/CF laminate with 12 layers (~ 1.8 mm)

Forming ends well before recrystallization of the material

Continuous-fiber reinforced thermoplasticsTemperature profile during non-isothermal stamp forming

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Continuous-fiber reinforced thermoplastics Quantification of wrinkles during stamp forming

Evolution of wrinkles during forming (experimental results for PPS/CF)

Source:T. Joppich, D. Dörr, et. al. “Layup and Process Dependent Behavior of PPS/CF UD Tape-Laminates during Non-Isothermal Press Forming Into a Complex Component ,” proceedings from ESAFORM Conference, Nantes, 2016

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplastics Draping simulation

Prediction of deformation behavior usingadvanced simulation methods

Model development using Abaqus

Validation via curvature and pointwisecomparison of distances

experiment simulation comparison

Cu

rva

ture

(ra

d/m

m)

Source:D. Dörr, T. Joppich, et. al. “A method for validation of Finite Element forming simulation on basis of a pointwise comparison of distanceand curvature,” proceedings from ESAFORM Conference, Nantes, 2016

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsMethodology to predict and evaluate shape deformations

56

Process- and material characterization

Variation ofdesign and processparameters

Deformation measurement

Prediction ofdeformations

Comparison ofscan data with

ideal geometry andsimulation

*

Scan data

CAD

Comparison

*

* Part design realized within BMBF SMiLE project

© Fraunhofer ICT

Slide 57

Variation of design and process parameters

Processing parts with different layups

Manufacturing of various part geometries

Application of different press forces and tool temperatures

Hybridization by combining long-fiber reinforced thermoplastics withunidirectional tape


* Part design realized within BMBF SMiLE project

*

© Fraunhofer ICT

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Process and material characterization

Conducting studies with varying process parameter sets

Investigating the influence of processing routes

Mechanical and thermo-analytical material characterization

Holistic evaluation of process chains


58

Recorded temperature profilesof a laminate‘s process cycle

DSC measurements of CF/PPS UD-tape

© Fraunhofer ICT

Slide 59

Deformation measurement

Designing and manufacturing of measurement-jigs

Validation of the measuring procedure

Generating measurements with tactile and non-contactmeasurement systems (coordinate measuring equipment, 3D laser scanning)

Postprocessing of generated data


59

Manufactured part 3D-Scanning of surface Digitalized partAlignment in jig

© Fraunhofer ICT

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Prediction of shape deformations

Simulation of a component‘s cooling behavior

Modelling the crystallization kinetics ofsemi-crystalline thermoplastics

Modelling of thermo-mechanical effects

Structural analysis to determine thermal stresses


60

Crystallization kinetics of a CF/PPS compositePrediction of shape deformations

due to a local patch reinforcement

© Fraunhofer ICT

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Comparison of scan data with ideal geometry andsimulation

Automated processes for alignment and analysis

Variance analysis of nominal geometry andcomponent‘s warpage

Developing interpretation routines and deriving characteristic parameters


© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsHybrid thermoplastic composites

Combination of local continuous-fiber reinforcements and established high-volume process technologies

Compression (LFT-D-CM) and injection molding

(LFT-D-IM, LFT-G)

Local reinforcement with continuous fibers

Final composite parts

Component was realized within theMAI Carbon cluster

© Fraunhofer ICT

Slide 63

Continuous-fiber reinforced thermoplastics Wound fiber structures – Local continuous-fiber reinforcement with fiber skeletons

Optimal fiber usage in thermoplastic components

Reduced content of the required fiber reinforcement saves weight and costs

No fiber damage by subsequently drilled holes

Load transfer and connection points allow an integral design

Linkage between component requirements, structural and topological optimization and bionic local reinforcements

© Fraunhofer ICT

Slide 64

Continuous-fiber reinforced thermoplastics Development of fiber skeletons to realize increased part complexity

1D

2D

Basic experiments for design guidelines

Injection molding technology demonstrator

Case study on complexity and processing guideline

3D3D3D

© Fraunhofer ICT

Slide 65

Continuous-fiber reinforced thermoplastics Development route for locally reinforced components

Use of FEM simulation

Collision detection

Division into sub-loops

Use of force cone and primary point method

Winding of fiber skeleton

Overmolding of reinforcement structure

3. Verification of structure

4. Manufacturing feas ibility study

1. Definition of constraints

2. Identification of load paths

5. Production

Design space

Loads

Boundary conditions

F1

F2

From design space to optimized lightweight structure

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Slide 66

From UD-tapes / fabrics to a passenger vehicle seat structure

Laminate optimization*

Tape-laying*

Pre-consolidation*

Trimming

In-mold-forming and

injection molding

*Process steps are necessary, if UD-tapes are used.

Continuous-fiber reinforced thermoplastics Case study: In-mold-forming an co-molding of a passenger vehicle seat structure

© Fraunhofer ICT

Slide 67

Continuous-fiber reinforced thermoplastics Case study: In-mold-forming an co-molding of a passenger vehicle seat structure

IR heaters

Pneumatic drawer

Laminate orfabric

Linear robot

Gripper

1. Heating to processing temperature

2. Transfer of clamping frame with a linear robot

3. Forming and injection molding

FClamping frame

Injection molding machine

© Fraunhofer ICT

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Continuous-fiber reinforced thermoplasticsCase Study – Locally reinforced vehicle floor section

Holistic approach to realize a highly-tailored structural thermoplastic component

Derive final des ign:LFT-D combined with local

UD-Tape reinforcements

Initial design based on lis t of requirements and

CAE methods

Component testing with multiple load cases

UD-tape

LFT-D

© Fraunhofer ICT

Slide 69

Economical Benefits of Tailored Thermoplastic Composites

Strength and Stiffness can reach close to the level of Epoxy based CFRP components

Complete flexibility in tailoring the part. Fiber orientation in any angle.

Local reinforcements possible Local use of UD tapes for structural optimization

High degree of functional integration does minimize the costs

Integration of inserts, rips, bossing etc. possible

Short cycle times of < 30s possible very high productivity

approx. 1 million parts a year in single part mode

Near net shape tape placement does minimize the waste – Large saving compared to textile based processes

Easy process with low level of down grade

Any waste can be directly recycled by feeding it back to LFT-D

© Fraunhofer ICT

Slide 71

Contact details

Prof. Dr.-Ing. Frank Henning

Deputy Director Fraunhofer Institute for Chemical Technology ICT

Director Department Polymer Engineering

Joseph-von-Fraunhofer Strasse 776327 Pfinztal, Germany

Phone: +49 721 4640 420Mail: [email protected]: http://www.ict.fraunhofer.de

Director Institute of Vehicle System Technology -Lightweight technology

Rintheimer Querallee 2, Building 70.0476131 Karlsruhe, Germany

Phone: +49 721 608 45905Mail: [email protected]: http://www.fast.kit.edu\lbt

Dr.-Ing. Timo Huber

Deputy Director Department Polymer Engineering

Joseph-von-Fraunhofer Strasse 776327 Pfinztal, Germany

Phone: +49 721 4640 473Mail: [email protected]: http://www.ict.fraunhofer.de

mailto:[email protected]

http://www.ict.fraunhofer.de/


http://www.fast.kit.edu/lbt


http://www.ict.fraunhofer.de/

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