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MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

Mahindra & Mahindra, Ltd.-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.
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Polypropylene Copolymer Material for Automotive Thin Wall Front Bumper with Integrated Grill Application

Mahindra & Mahindra, Ltd.-Karthik Govindaraj, Ashish Junankar, Rao Venkateshwara, Vijay Papanal
Published 2018-04-03 by SAE International in United States
This paper describes modified polypropylene copolymer (PPCP) material for thin wall front bumper development (2.5 mm) with integrated grill in automotive application. This compounded PPCP material has optimized flow behavior, tensile strength, modulus, impact strength, and thermal properties to meet the functional requirements. This is a ready to mold material used in injection molding process. Front bumper and grill are functional components with slow speed impact requirement to absorb impact in real world. These parts have precise fitment requirement under sun load condition. Front bumper is also having other critical criteria with respect to vehicle variants such as aesthetic mold-in-color finish as well as painted finish. Grill has air entry performance criteria to ensure cooling efficiency in intercooler compartment.In this paper, PPCP material filled with talc filler has been explored for thin wall front bumper part with a wall thickness of 2.5 mm and with an integration of functional grill part. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analyzed by using mold flow…
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Polypropylene Copolymer Automotive Canopy Plastic Structure Application

Mahindra & Mahindra, Ltd.-Karthik Govindaraj, Kakade Ritesh, Ramadas Narayanan, A Rajkumar, Venkatesan D
Published 2018-04-03 by SAE International in United States
This paper describes modified polypropylene copolymer (PPCP) material for canopy plastic structure in a modular commercial passenger vehicle. This compounded PPCP material has optimized flow behavior, tensile strength, modulus, impact strength, and thermal properties to meet the functional requirements. Material described in this paper is a PPCP compound reinforced with glass fiber and mica filler. The application described in this paper is a canopy plastic structure, which is a structural exterior plastic part. Canopy plastic structure acts as a structural frame to hold vinyl canopy in both sides and tail gate of vehicle.In this paper, PPCP has been explored for canopy plastic structure part against conventional polyamides. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analyzed by using mold flow analysis. Product performance was validated for predefined key test metrics such as structural durability, torquing, thermal aging and cold impact. This part met required specification. This PPCP material based canopy plastic structure part has various benefits such as potential weight reduction (15%),…
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