FEM DaimlerChrysler S-Class Coupe in GMTex · 2009. 6. 8. · Quadrant AG 2007 - Company...

Quadrant AG 2007 - Company confidential information 17th Annual SPE Conference Detroit 2007

FEM DaimlerChrysler S-Class Coupe in GMTex

11.-13.09.22077th annual SPE ConferenceDetroit

Contact for information: Karl-Heinz KALMBACHLeader Business line Exterior and StructuresQuadrant Plastic Composites AG Phone +41.(0)62.885 83 22P.O. Box Fax +41.(0)62.885 83 62Hardstrasse 5 Mobile +49.(0)172.6283342CH-5600 Lenzburg 1 e-mail [email protected]


Agenda

• Quadrant Company Information

• GMT/GMTex Materials

• FEM in GMTex

SPE Conference 2007


Quadrant Company Information

SPE Conference 2007



Business Polymer Materials Processing

(Thermoplastic Semi-finished and Finished Products)

Net Sales CHF 750 Mio (2006)

Customers 75% Broadly Diversified, 25% Automotive

Business Divisions High-Performance Plastics (QEPP/QCMS)

Plastic Composites (QPC) / Cable Protection Systems (QCPS)

Market Position Leading in all Areas of Activity

Regional Headquarters Lenzburg (CH), Tielt (B), Reading (PA / USA), Hongkong

Employees 2’400

Ownership Directors / Management (19%)

> 1’000 Institutional and Private Shareholders (81%)

SPE Conference 2007


HIGH-PERFORMANCE PLASTICS PLASTIC COMPOSITES /CABLE PROTECTION SYSTEMS

80% 20%

World Leaderin Engineering Plastic Shapes

for Machining

Top Ten Europein Technical Injection Moulding

widely diversifiedMachinery & Equipment

Manufacturing, Electrical & Electronics, Medical, Automotive

Engineering Plastic Shapes- AEP-GEP-U-PE (Poly Hi Solidur)

Technical Components & Technical Systems from

Engineering Plasticssemi-finished products & parts finished products

QEPP QCMS QPC QCPS

Swiss LeaderWorld Leaderin Glass Mat Thermoplastics

(GMT)in Cable Protection

Systems

Glass Mat Thermoplastics (GMT) & Low Weight Reinforced

Thermoplastics (SymaLITE)

Cable Protection Systems(Symalit Brand)

semi-finished products finished products

Automotive Utilities, Telecom, Construction

Products

Market Position

Division

Key Markets

Business

Net Sales

Operating since 1933 1933 1978 1952

Employees ≈2’100 ≈300


SPE Conference 2007


GMT/GMTex Materials

SPE Conference 2007


Material grades for structural applications

GMT/GMTex Materials

GMT GMT-UD GMTex S-TEX

A100F20..40B100F30..40 C100F20..40D100F20..40E100F30..40G100F30 (UV)

Slimtec

C100UD42C100UD45C100UD50

X101F40 X102F40X103F40

X101F40 +-45°

X102UD40

S-TEx50% 1.6S-TEx50% 2.0

Advanced GMT

SlimTEC

Q-TEX

Q-TEX50% 4/1 0/90°

UD

Q-UD 50% 2.0 mm

SPE Conference 2007


Material properties

• Fiber lengths > 25 mm

• Fiber network in 3D

• Long fiber content in the final parts

• Extensively isotropic

• Low CLTE

• High strength compared to short fiber materials

• Especially high impact resistance

• Temperature range in between -30° to 130° C

• Good fatigue properties vs. Al / metal

X-Ray measurement

GMT/GMTex Materials

GMTex grades with 1/1 reinforcement weave

UD reinforcement

SPE Conference 2007


GMT/GMTex processing

• Different GMT/GMTex gradesin one part applicable

• Different wall thicknessesin one part feasible

• Short cycle times

Use of the fittest material inthe part area where youreally need it

GMT/GMTex Materials

GMT/GMTex processing

GMTex

GMT

GMTex

Wall thickness 1

Wall thickness 2

Wall thickness 3

SPE Conference 2007


Static and dynamic material behavior

• Wide spectrum of material properties

depending on material configuration

• High energy absorption especially

in high dynamic areas

GMT/GMTex Materials

GMTex 40 4/1 middellayer

0

50

100

150

200

250

0.00% 1.00% 2.00% 3.00% 4.00% 5.00% 6.00%

Dehnung [%]

Sp

annu

ng[M

Pa]

0.01[1/s]2[1/s]20[1/s]20[1/s]korr

GMTex 55 1/1 top layer

0

50

100

150

200

250

300

350

0.00% 1.00% 2.00% 3.00% 4.00% 5.00% 6.00% 7.00%

Dehnung [%]

Spa

nnu

ng[

MP

a]

0.01[1/s]2[1/s]20[1/s]20[1/s]korr

GMT40

0

20

40

60

80

100

120

140

160

0.00% 1.00% 2.00% 3.00% 4.00% 5.00%

Dehnung [%]

Spa

nn

un

g[M

Pa]

0.01[1/s]2[1/s]20[1/s]20[1/s]korr

SPE Conference 2007


High heat GMT

GMT/GMTex Materials

SPE Conference 2007

Impact Charpy at RT

Tensile Tensile

Compressive Compressive

RT 80°C

1.5

3.0

4.5

6.0

20 40 60 80

1.0

1.1

1.3

6060

90

30

30

45

60120

30 15

90

120

306090120

1.0

2.0

3.0

4.01.2

Values given for 4.0mm thick flow-moulded plates


GMT/GMTex Materials

Plastic hybrids / Plastic-Metal hybrids

• Material core PP-fiber/glass fiber blend

• Top layers SymaLITE core with Q-Tex layer at the bottom

• Area weight 2400 g/m2 in total

• Density depending on wall thickness

• Wall thickness circa 8 mm

Q-Tex~ 2mm

SymaLITE~ 6mm

Total wall thickness ~ 8mm

Decor part in different materials feasible

SPE Conference 2007


FEM in GMTex

SPE Conference 2007


> 2000

Injectionmolding

D-LFT

> 2006

Compressionmolding

GMT/GMTex

< 1990

CompressionMolding

GMT

> 1990

CompressionMolding

LFT

FEM DC S-Class Coupe

Composite front end history

• GM• VW

• VW• Audi

• PSA• Smart

• DC• ..

SPE Conference 2007


OEM requirements for GMTex FEM

• High safety standards

• High stiffness and dimensional stability

• Good fatigue behaviour up to 130°C

• Good impact behaviour

• No additional steel reinforcements

• Removable midsection to simplify the engine maintenance

• Good surface appearance, no corrosion protection

• Temperature resistance up to 130°C

• Weight saving

• Cost competitiveness

• Recyclables


SPE Conference 2007



Product information

• Weight 3.4 kg

• Wall thickness 3.0 – 25 mm

• Functions

– Fixation of hood lock (6000 N)

– Fixation of radiator and lamp housing

– Controlled energy absorption

– Good dampening behaviour

– Especially developed inserts for optimized assembly stability

SPE Conference 2007



Pre-assembled upper carrier with lamp housings

substitution of 12 steel/aluminum parts with 3 GMT/GMTex parts

weight saving versus aluminum: 600 g

weight saving versus steel: 3000 g

Lamp housing rh

GMTex

Lamp housing lh

GMTex

Upper carrier

GMTex

SPE Conference 2007


Lamp housing rh

GMTex

X121F40


Single parts of composite components in GMT/GMTex

Lamp housing lh

GMTex

X121F40

Upper carrier

GMTex

X121F40

X101F52

SPE Conference 2007



Material design GMTex

Weave inlay with endless glass fibers

GMT with random fibers on top

SPE Conference 2007


Visible areas at open hood with grained surface

Surface with no grain

Surface grained


SPE Conference 2007


Outlook new GMT materials - High heat GMT/GMTex

• High temperature GMT

– Mineral filled GMT

– PP-PA blend

– PA-GMT

• Weave reinforced GMT

– Super GMTex

– Thin weave reinforced GMT


1.20

90

Impact CharpyStrength (KJ/m2)

Strength (MPa)

E-Mod (GPa)

Density molded (g/cm3)

E-mod (GPa)

Strength (MPa)

B100 F30 F1, 30% GF

B110 F31 N22, 30% GF

B100 F30 M11, 28% GF

D100 F40 F1, 40% GF

1

2

3

4

5

1

2

3

4

5

1.04

1.08

1.12

1.16

50

60

70

8060

110

120

13090

50

140

100

70

80

FlexuralTensile

SPE Conference 2007


Conclusions

SPE Conference 2007


Conclusions

• GMT/GMTex grades are dedicated for structural components with high dynamic loads

• Due to compression molding process different GMT/GMTex materials are applicable in the open mold

• The use of the right materials on the right position is easily achievable

• Different wall thicknesses in one part are possible

• Good crash performance is given which is substantial for structural applications

• High level of functional integration with flow molding compression molding is also possible even with weave reinforced grades

• High quality surface achievable even with weave reinforced materials

• Cost competitiveness is given by integration of functions

• New material developments are in the pipeline, e.g. LWRT structural applications and high heat GMT, to cover a broad range of structural applications

SPE Conference 2007

FEM DaimlerChrysler S-Class Coupe in GMTex · 2009. 6. 8. · Quadrant AG 2007 - Company...

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