UTILIZING ADVANCED COMPOSITE · PDF fileUTILIZING ADVANCED COMPOSITE ... Institute for...

SEPTEMBER 25TH 2017

Beispielbild –passendes Bild einfügen

UTILIZING ADVANCED COMPOSITE

TECHNOLOGY

Paul Thom, Sales and Product Manager Hydraulic Press Systems

E-Mail [email protected] Mobile +1 734 680-7555

Dipl.-Ing. Patric Winterhalter, Product Manager Composites

E-Mail [email protected]

9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY 1

UTILIZING ADVANCED COMPOSITE TECHNOLOGY


AGENDA

COMPANY

MOTIVATION

PROCESSES AND REQUIREMENTS

ALWAYS THE RIGHT SOLUTION – SCHULER COMPOSITE PRESSES

COMPOSITES ALLIANCE

FUTURE TREND

PARTNERSHIPS WITH R&D FACILITIES

SCHULER AT A GLANCE


• Technological and global market leader in the forming

industry

• Annual sales 1,200.0 mio. € with 6,700 employees

• Top-tier customers: Car manufacturers and their suppliers,

packaging, household equipment, aerospace, minting

• Global footprint: Several sales and service locations in the US

Extract customer references

MOTIVATION

4

UTILIZATION OF LONG FIBER REINFORCED PLASTICS

Fiber reinforced plastics

Tremendous weight saving potential

Integration of functions and/ or complex shapes

Reduced mold cost ideal for low to mid volumes

Using compression molding processes with a press

Not too low volumes (> 1,000)

Automatic and economical production feasible

High performance parts (with long and endless fibers)

August 18 2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY

Lightweight potentials of materials Source: Audi AG

OVERVIEW OF COMPOSITE RAW MATERIALS


Reinforcement

Shortfibre Longfibre EndlessfibreFibres

Aramid

Carbon

Glas

Metal

Plastic

Mineral

Natural

…….

Resins

Ceramic

Thermoset

Thermoplastic

Elastomer

Metalic

Concrete

…...

OVERVIEW COMPOSITE PRODUCTION PROCESSES

6Source: BMW and BASF

Thermoset matrix Thermoplastic matrix

Long fiber< 50 mm

SMC / C-SMC GMT / LFT / LFT-D

Endless fiber> 50 mm

HP-RTM / wet-RTM / prepreg Organic sheet / Tape

Hybrids

9/26/2017 UTILIZING ADVANCED COMPOSITE TECHNOLOGY

7

Thermoset Thermoplastic

GeneralRequirements

Uniform wall thickness of partsDwell time & accurate Position and Parallelism controlHigh mold opening force & mold temperature control

Variety of die functions & all in one single press operation

Random fiber orientation

high slide speedshort closing time

continuous slide motionfast pressure build-upDedicated fiber

orientationresin injection

mold evacuation

DIFFERENT JOBS – DIVERSITY OF PROCESSES


EXAMPLE - SCHULER CLASSIC PRESS


Eleven production lines for HP-RTM process

Classic design of press

Serial production with 25,000 cars per year

Approx. 6 min cycle time

Automatic tool change

LARGE SCALE HP-RTM MANUFACTURING LINES

Source: BMW

9

Thermoset Thermoplastic

GeneralRequirements

Uniform wall thickness of partsDwell time & accurate Position and Parallelism controlHigh mold opening force & mold temperature control

Variety of die functions & all in one single press operation

Random fiber orientation

high slide speedshort closing time

continuous slide motionfast pressure build-upDedicated fiber

orientationresin injection

mold evacuation

DIFFERENT JOBS – DIVERSITY OF PROCESSES


THE NEW SCHULER COMPACT PRESS DESIGN

10

MAIN CHARACTERISTICS

Reduced building costs

Use of existing building with reduced height

Highest output

Minimal parts rejection

Flexibility

Presses capable for all processes

Reduced operating costs

Energy efficient production

Compact Schuler press 36,000 kN with 3.6 x 2.4 m platen surface


90,000 kg

HIGH QUALITY PARTS NEED HIGH PRECISION PRESSES

11

HIGH POSITION AND PARALLELISM ACCURACY

Parallelism accuracy0.05 mm equal to “1 hair”

Position accuracy0.05 mm equal

to “1 hair”Crosswind


MULTIFUNCTIONAL HYDRAULIC COMPACT PRESS

USED ALL OVER THE WORLD

NCC

National Composite Center

Bristol, England

CHAPU-3600-3.6x2.4

AZL

The Aachen Center for Integrative

Lightweight Production

Aachen, Germany

CHAPU-1800-2.8x1.8

IACMI

Institute for Advanced Composites

Manufacturing Innovation

Detroit, USA

CHAPU-3600-3.6x2.4

OEM

R&D Department and

series production

Republic Korea

CHAPU-3600-3.6x2.4

Installation right nowIn use since 2017


In use since 2014 In use since 2017

TURN-KEY COMPOSITE MANUFACTURING LINES


Material Feeding Cutting Heating Presses

Handling3D CuttingResin Injection Moulds

Concentration of FRIMO’s and Schuler’s know-how and experience in the processing of FRP

The Alliance provides customized turnkey solutions for manufacturing of light-weight components in series production delivered

by a single source

SAMPLE – THERMOSET APPLICATION

14

LARGE SCALE HP-RTM MANUFACTURING LINE

Material Cutting Alignment Heating Preforming3D

CuttingRTM

Injection3D

CuttingPostprocess


TREND OF HYBRID PART MANUFACTURING


COMBINATION OF HOT STAMPED STEEL AND FIBER REINFORCED PLASTICS

=Hot stamping of steel Fiber reinforced plastics Hybrid parts

Schuler can deliver turnkey systems for hot stamping, composite and hybrid manufacturing

We can develop hybrid parts together with you

SCHULER MEMBERSHIPS


WE ARE MAKING THE RESULTS OF RESEARCH

RELEVANT FOR YOUR DAILY PRODUCTION

Consulting along the whole process chain

(material, process, quality control, joining, etc.)

Joint product and process development

Prototyping and process start-up

Production capacity available

WE ARE MEMBERS IN MANY IMPORTANT RESEARCH INSTITUTES

Our capability to innovative is the main pillar of our market success

Source: NCC

SUMMARY


UTILIZING ADVANCED COMPOSITE TECHNOLOGY

There is a motivation using composites in the automotive industry

Equipment of Schuler for R&D and high volume production well proven over many years

Schuler offers high precision presses for high quality parts

Innovative compact press with highest output, great flexibility and reduced operating costs

Turnkey composite manufacturing solutions in collaboration with Composites Alliance partner Frimo

Partnership with R&D facilities all over the world to support our customers

Thank you for your attention!

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