Composites Forum Endless Fiber Reinforced …...Carbon Fiber Glass Fiber Akulon PA6 ≤ 60 wt.% CF ≤ 65 wt.% GF Akulon PA66 EcoPaXX PA410 Xytron PPS Stanyl PA46 ForTii ACE PPA Endless

© ika 2018 · All rights reserved2018/11/07Slide No. 1#150 · 18rm0008.pptx

Stuttgart, 07. November 2018

Ralf Matheis, Lutz Berger, Thorolf Schulte

Endless Fiber Reinforced Thermoplastic Composites in E-mobility Applications

Institute for Automotive Engineering

Giacomo Perfetti, Ulrich Heisserer, Raj Mathur

DSM Engineering Plastics B.V.

Composites Forum


Agenda

Motivation of Lightweight Design for Electric Vehicles

Endless Fiber Reinforced Thermoplastic Composites

Potentials of TPC in Vehicle Applications

Simulation Approaches

Summary


Motivation of Lightweight Design for Electric VehiclesPropulsion Systems - Market Development in Europe until 2030

2020Powertrains with traditional ICE will

be almost completely substituted by

micro hybrids

2025Significantly grown market shares for

mild hybrids (>30%), PHEVs (>10%)

& BEVs (<10%)

2030Majority of vehicles still with ICE but

almost all powertrains hybridised.

Market share for BEVs <20%.

Battery technology

> Energy density

> Battery costs

> Charging speed

Charging infrastructure & technology

Regulations

Regional and temporary driving bans for ICE vehicles

> Zero emission zones

Development of oil price

Buying & driving behavior

> Ecological awareness

> Shared mobility

> Premiums, tax & toll benefits

Influences on

market shares of

PHEVs & BEVs

Images: auto

evolu

tio

n.c

om

, conductix.c

om

, hx-g

lobal.com

, dpa.c

om


Motivation of Lightweight Design for Electric VehiclesSignificance of Lighweight Design for Propulsion Concepts

Lightweight

Design*

37 kg

Rolling

Resistance

0.23‰

Front

Surface A

0.055 m² 7

cw-points

Secondary

consumption

43 W

Powertrain

efficiency

0.48 %

∆ 1% driving range

Reference: BEV, m = 1600 kg, WLTP

Lightweight

Design*

36 kg

Rolling

Resistance

0.56 ‰

Front

Surface A

0.12 m² 14

cw-points

Secondary

consumption

49 W

Powertrain

efficiency

0.2 %

∆ 1% fuel reduction

Reference: ICEV, m = 1270 kg, NEDC

Lightweight design remains important but efforts in other domains will have a higher impact on efficiency

∆ 2.8%

∆ 5.3% ∆ 5.25%

∆ 24.6%

∆ 8%

∆ 2.3%

∆ 3.35%

∆ 21.5%

∆ 2.5% ∆ 2.5%

*without secondary effects


Advanced materialsInnovative design and production concepts

Innovative concepts for vehicles,

systems and components, e.g.:

Micro vehicles

Integral design replacing

differential design

Functional integration, e.g.

adding intelligence

…

Optimum geometry, balancing

material stress in a component:.

Optimizing component topology

Variation in material thickness

Combination of materials

multi-material design

…

Lightweight Lay-out

Making use of advanced

manufacturing technologies

Innovative forming processes

Additive manufacturing

Novel casting technologies

…

Lightweight Production

Replacing conventional materials

by lighter and more advanced

materials:

Replacing steel e.g. by ultra

high strength steel

Replacing steel by light metals

Replacing metals by fibre

reinforced plastics

Composites from steel and

other materials

…

Lightweight Materials

+ + +

Motivation of Lightweight Design for Electric VehiclesLightweight Approaches

Lightweight Concepts


Agenda

Introduction ika





Summary


MatrixCarbon Fiber

Glass Fiber

Akulon

PA6

≤ 60 wt.% CF

≤ 65 wt.% GF

Akulon

PA66

EcoPaXX

PA410

Xytron

PPS

Stanyl

PA46

ForTii ACE

PPA

Endless Fiber Reinforced Thermoplastic CompositesDSM UD Tape Portfolio

New innovative materials will enable

Highest performing polyamide

Best chemical resistance

Strong conversion economics

Significant initial OEM approvals

Str

ength

[M

Pa]

Elongation at Strength [%]


Endless Fiber Reinforced Thermoplastic CompositesDSM UD Tape Portfolio

Lead times and delivery conditions

Typical 6 – 8 weeks

Tape Specifications Typical Values Remarks

Thickness 0.20 – 0.30 mm (typical for CF)

0.25 – 0.30 mm (typical for GF)STD: +/-0.02 mm

Width Up to 600 mmSlitting to achieve

narrow width

Length Any length possible

Slitting ≥ 6 mm +/- 0.1 mm1 mm incremental

step

Samples are made fit-for-purpose on project basis


Endless Fiber Reinforced Thermoplastic CompositesDSM UD Tape: Complete Data Package Available

CAE Input Decks

In Situ Consolidation Winding & Tape Placement

Processing Guidelines

Hot-pressing and Thermoforming-Over-molding

Processing Guidelines

Materials qualified for automotive and used in

door, floor, front-ends, cross-car beam


Endless Fiber Reinforced Thermoplastic CompositesUD Tape Processes

Tape winding of parts with rotational

symmetry (cylinders, tubes, box-beams etc.)

Automatic Tape Laying (ATL) (panels, sheets,

etc.)

ATL panels are thermoformed to net

shape

ATL panels are over-molded with

structural features (ribs, etc.)

ATL and thermo-forming and over-molding;

the UD tape or the consolidated laminate is

placed in injection-mold as insert for localized

reinforcement by over-molding

Hybrid metal-composite construction

(composite patches glued to metal)

Tape winding & tape placement

Thermo-forming & overmolding

UD tape

production

Process

know-how

Application

know-how

UD tape

production

Process

know-how

Application

know-how


Agenda

Introduction ika





Summary


Potentials of TPC in Vehicle ApplicationsStructural Parts in Body and Chassis: Basic Segmentation

Body-in-white structural parts

• Front end modules

• Structural RF inserts

• Pillars & side sills

• Longitudinal and cross beams

Crash Management System

• Crash impact beam

• Lower bumper stiffener & bumper beams

• Crash cones

Hang-on parts

• Transmission beam

• Suspension beam

• Door beam

Semi-structural

• Spare wheel recess

• Floor pans

• Underbody shields

• Fire walls

Seating structureMany different materials and technologies:

Metals – Thermoset, PP, PA6 (CF of GF)

Chassis

Roof module

Structural

body parts

Structural

interior parts


Potentials of TPC in Vehicle ApplicationsOngoing Applications at DSM

Examples

Maxion Hybrid Wheel

Passenger cars

Light weight commercial vehicle

Trucks

TYPE IV Composite Pressure Vessels

EU-Project ENLIGHT

More application under NDA…

Well established technology partners in supply chain

Slitting

Winding and tape placement

Weaving

AZL Consortium

(Aachen Center for Integrative Lightweight Production)

AVK – Thermoplastic Composite Standardizations


Potentials of TPC in Vehicle ApplicationsProject ENLIGHT

ENLIGHT - Enhanced Lightweight Design

(Research project funded by the European Union)

Sustainable lightweight design of vehicle body

modules for series production in future electric

vehicles (ca. 50.000/year, horizon: 8 – 12 years)

Application of innovative lightweight materials

Significant mass reduction compared to metal intensive

lightweight design

Funded by

the Seventh Framework

Programme

of the European Union


Potentials of TPC in Vehicle ApplicationsProject ENLIGHT

Carbon fibre reinforced PA 410

(UD tapes and fabric woven from

tapes)

Structural panels and tape-wound

side impact beam over an extruded

permanent mandrel

Components thermoformed and

adhesively joined

60% lighter than state of the art

steel-based design

Fulfilling same requirements

Demonstrator vehicle

door panel

Carbon fibre reinforced PA 410

UD tapes based ply-books

thermoformed to the final shape

18% lighter than state of the art

steel-based design

Fulfilling same requirements

Composite strength and

dimensional stability are not

affected by E-coating process

Demonstrator central floor

Conventional aluminium crashbox

Combination of metal profile, CFRP

inlay and CFRP closing sheet

Local reinforcements/thickness

reduction of cross member

Tested in dynamic pole impact

Steel-CFRP Hybrid: 43 % mass

reduction

Aluminium-CFRP Hybrid: 35 %

mass reduction (further potential

identified)

Hybrid bumper cross

member

Combination of aluminium profile

and CRFP crash tube

Utilisation of energy absorption

capability of CFRP

Structural integrity due to the

higher ductility of aluminium

Conventional mounting in vehicle’s

front structures

Aluminium-CFRP Hybrid offers

potential for increasing of the

specific energy absorption

The project showed improvement

of 61 % compared to one-chamber

aluminium profiles

Hybrid longitudinal

member


Agenda

Introduction ika





Summary


Simulation ApproachesMaterial Modelling of FRP

Automotive application of Materials requires

adequate modelling approach using the FEM

Choice of material model depends on

properties and failure modes that are to be

captured

For the Thermoplastic tapes the LS-DYNA

material model

*MAT_LAMINATED_COMPOSITE_FABRIC

(*MAT_058) has been chosen

This established model considers:

Degradation of material properties due to

micro-cracks

Failure due to fiber rupture/kinking and

matrix cracking

Tension, compression and shear

Modelling Approach

List of input properties

Material Characterisation

Model input data

Validation/Calibration

Validated solver

card

Application

Material models for PA6 GF60 tapes in conditioned and unconditioned state


Simulation ApproachesMaterial Card

MID RO EA EB EC PRBA TAU1 GAMMA1

GAB GBC GCA SLIMT1 SLIMC1 SLIMT2 SLIMC2 SLIMS

AOPT TSIZE ERODS SOFT FS EPSF EPSR TSMD

E11C E11T E22C E22T GMS

XC XT YC YT SC

*MAT_LAMINATED_COMPOSITE_FABRIC

Density (ISO 1183)

Tension 0° (DIN EN ISO 527-5)

Tension 90° (DIN EN ISO 527-5)

In-Plane Shear

(DIN EN ISO 14129)

Compression 0°

(DIN EN ISO 14126)

Compression 90°

(DIN EN ISO 14126)

Iterative calibration for

3-Point-Bending

(DIN EN ISO 14125) /

penetration test

Default / no adaption /

experience values


Simulation ApproachesModel Set-up

All tests required for *MAT_058

calibration are modelled

5 mm mesh

Fully integrated shell elements

One integration point per layer

(*PART_COMPOSITE)

Evaluation of nodal displacements,

sectional forces and respectively

contact forces

Stresses and strains calculated using

the basic dimensions of the

specimens

Tension 0°/90°/45° Compression 0°/90°

Three Point Bending Pentetration Test


Simulation ApproachesSimulation Results (Dry)

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Str

ess [M

Pa

]

Str

ess [M

Pa

]

Strain [%]

Str

ess [M

Pa

]

Strain [%]S

tre

ss [M

Pa

]Strain [%]

Strain [%]

Compression 0°

Tension 0°

Tension 45°

Tension 90°


Simulation ApproachesSimulation Results (Dry)

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Com

pre

ssio

nS

tre

ss [M

Pa

]

Longitudinal Strain [%]

Fo

rce [kN

]

Displacement [mm]

Fo

rce [kN

]

Displacement [mm]

Compression 90°

Pentetration Test

Three Point Bending


Simulation ApproachesSimulation Results (Conditioned)

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Str

ess [M

Pa

]

Str

ess [M

Pa

]

Strain [%]

Str

ess [M

Pa

]

Strain [%]S

tre

ss [M

Pa

]Strain [%]

Strain [%]

Compression 0°

Tension 0°

Tension 45°

Tension 90°


Simulation ApproachesSimulation Results (Conditioned)

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Test 1

Test 2

Test 3

Test 4

Test 5

Sim.

Com

pre

ssio

nS

tre

ss [M

Pa

]

Longitudinal Strain [%]

Fo

rce [kN

]

Displacement [mm]

Fo

rce [kN

]

Displacement [mm]

Compression 90°

Pentetration Test

Three Point Bending


Agenda

Introduction ika





Summary


Summary

Lightweight will remain a key driver for vehicle innovation

With regard of the energy efficiency of electric vehicles lightweight design plays an important roll

Other domains will have an higher impact than they used to have for vehicles with combustion

engines

Endless fiber reinforced products offer high lightweight potential for to load appropriate design

Several endless fiber reinforced tapes for automotive application available by DSM

Various application fields in BiW, hang-on parts, semi-structurals and seating

Automotive application of materials requires adequate modelling approach using the FEM

Material models for PA6 GF60 tapes in conditioned and unconditioned state are available for the

solver LS-DYNA


Phone

Fax

Email

Internet www.ika.rwth-aachen.de

Institute for Automotive Engineering (ika)

RWTH Aachen University

Steinbachstr. 7

52074 Aachen

Germany

Contact

Dipl.-Ing. Ralf Matheis

+49 241 88 61121

[email protected]

Phone

Email

Internet www.dsmep.com

DSM Engineering Plastics Europe

Urmonderbaan 22

6167 RD GELEEN

Netherlands

Giacomo Perfetti, PhD

+31 6 83649747

[email protected]

Documents

Composites Forum Endless Fiber Reinforced …...Carbon Fiber Glass Fiber Akulon PA6 ≤ 60 wt.% CF ≤ 65 wt.% GF Akulon PA66 EcoPaXX PA410 Xytron PPS Stanyl PA46 ForTii ACE PPA Endless