This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Development of an Epoxy Carbon Fiber Reinforced Roof Frame Using the High Pressure Resin Transfer Molding (HP-RTM) Process
Technical Paper
2020-01-0773
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
Composites technology for the automotive market continues to advance rapidly. Increasing knowledge of composite design, simulation tools, new materials and process equipment are all contributing to make composites better performing and more affordable for mass-produced vehicles. In particular, the high pressure resin transfer molding (HP-RTM) and related liquid compression molding (LCM) processes are enabling manufacturers to produce complex composite parts at shorter and shorter cycle times.
This paper describes the development of an epoxy carbon fiber roof frame targeted for future vehicle production. Several composite processes were considered for the roof frame. The case illustrates that when the (product) design, material and process are considered together, a high-performing, cost-efficient part can be produced. The resulting carbon fiber roof frame met all OEM performance requirements and economic targets while weighing 44% less than the original design in magnesium and 32% less on the overall assembly. The part was the first HP-RTM part successfully demonstrated in North America and stands as a model for future lightweighting developments.
Of equal significance, the development process for the part involved a unique collaboration of companies throughout the automotive composites value chain. Each company contributed their particular expertise to the project including resin technology, reinforcement solutions, engineering analysis, process simulation, tool construction, preforms and molding. The collaboration enhanced the speed and technical success of the overall development.
Authors
Topic
Citation
Ball, C., Greydanus, S., Swentek, I., and Nara, K., "Development of an Epoxy Carbon Fiber Reinforced Roof Frame Using the High Pressure Resin Transfer Molding (HP-RTM) Process," SAE Technical Paper 2020-01-0773, 2020, https://doi.org/10.4271/2020-01-0773.Data Sets - Support Documents
| Title | Description | Download |
|---|---|---|
| [Unnamed Dataset 1] | ||
| [Unnamed Dataset 2] | ||
| [Unnamed Dataset 3] | ||
| [Unnamed Dataset 4] |
Also In
References
- Hillermeier, R.W., Hasson, T., Friedrich, L., and Ball, C., Momentive Specialty Chemicals, “Advanced Thermosetting Resin Matrix Technology for Next Generation High Volume Manufacture of Automotive Composite Structures,” in 12th Annual Society of Plastics Engineers Automotive Composites Conference and Exhibition, Troy, MI, 2012.
- Brzozowski, A., Ford Authority, “Ford F150 Production Cut as Parts Supplier Recovers from Fire,” http://fordauthority.com/2018/05/ford-f-150-production-cut-as-parts-supplier-recovers-from-fire/, Detroit, MI, May 2018.
- “Plasan Carbon Composites,” http://www.plasancarbon.com, Novi, MI, 2019.
- Hexion, Inc., https://www.hexion.com/en-us/who-we-serve/automotive, Columbus, OH, 2019.
- Staargaard, J., Plasan Carbon Composites, Keynote Presentation “From Hours per Part to Parts per Hour,” in 16th Annual Society of Plastics Engineers Automotive Composites Conference and Exhibition, in Novi, MI, 2016.
- Forward Engineering, GmbH, https://www.forward-engineering.com/en/, Munich, Germany, 2019.
- iXent, GmbH, Engineering Services, https://www.ixent.de/index_en.html, Munich, Germany, 2019.
- Sigmatex Carbon Textile Solutions, Inc., https://www.sigmatex.com/automotive1, Orangeburg, SC, 2019.
- Zoltek Corporation, a Toray Group Company, https://zoltek.com/applications/automotive/, Bridgeton, Missouri, USA, 2019.
- ESI Group,PAM-RTM, “Composites Molding Simulation Software,” https://www.esi-group.com/software-solutions/virtual-manufacturing/composites/pam-composites/pam-rtm-composites-molding-simulation-software, Farmington Hills, MI, 2019.
- Alpex Technologies, GmbH, https://www.alpex-tec.com/en/alpex-automotive.html, Mils, Austria, 2019.
- Diffenbacher GmbH Maschinen- und Anlagenbau, https://dieffenbacher.com/en/composites/technologies/hp-rtm-high-pressure-resin-transfer-molding, Eppingen, Germany, 2019.
- Fraunhofer Institute for Chemical Technology, Pfinztal, Germany and Fraunhofer Project Centre for Composites Research at Western University, https://www.ict.fraunhofer.de/en/comp/fpc_ontario.html, London, Ontario, Canada, 2019.
- KraussMaffei Technologies, GmbH, https://www.kraussmaffei.com/en/our-processes/high-pressure-resin-transfer-molding-hp-rtm, Munich, Germany, 2019.