Compression Moulding with PtFS for Automotive

Applications

SAMPE UK & Ireland Chapter, Annual Seminar

Cranfield, 23rd February 2017

Surface Generation

• Established 2002

• Based in Rutland

• 32 employees

• PtFS technology offers zonal, responsive and efficient thermal control solutions

principally for polymer processing

• Target sectors include; aerospace, automotive, consumer electronics, oil & gas

Overview of PtFS Technology

Zoned Tool Face

Controlled Shop Air

Heater Power

Controller

PtFS Tool Face

PtFS Mould Base

PtFS Mould Base

Inline

Heater

< 4 Zones Across >

< 4

Zones

Dow

n >

Thermocouple Leads

Mould Base(Compression Moulding)

Applications of PtFS Technology

Open Moulding Closed Moulding Injection Moulding

AMSCI LX Collaborative Programme

• Advanced Manufacturing Supply Chain Initiative (AMSCI)

• LX Program, lead partner Sigmatex

• Circa £7m budget

• Output; Create 238 new job opportunities & safeguard 144 existing jobs

• 18 month program due to finish May 2017

• Sponsoring automotive OEM’s; Bentley, Emerald Automotive & Nissan

SG Involvement in LX

• WP11 – Low Speed Energy Absorber

• SG, Engenuity, Liberty Advanced

Composites, LMAT InCA

• WP8 – Pedal arm

• SG, Engenuity, LMAT InCA, Cranfield

• Candidate technologies were constrained

for both work packages by partner

capability, budget etc..

• Scope for both WP’s includes design,

manufacture, functional test & economic

study

WP8 – Outline

• SG objectives; to demonstrate PtFS technology with short fibre moulding compounds

& complex geometries

• ENG objectives; to develop and evaluate analysis techniques to mitigate the

degradation of allowable properties when dealing with random fibre architecture

materials

• Criteria for success; mass reduction without compromising function or cost

• Working to;

• Defined interface requirements

• 2 principal static & 1 dynamic load case

• Existing mass of pedal arm 855g

• Cost target circa £10/kg

fore/aft load application

lateral displacement

WP8 – Candidate Materials

• 5 candidate material

solutions identified

• Various criteria assessed

through evaluation of

materials

A B C D E Priority

Thermoset (TS)/

Thermoplastic (TP)TS TS TP TP TP

5=high

1=less so

Flow behaviour 5 1 3 4 2 5

Charge preparation 3 2 4 5 1 2

Storage 2 1 5 5 3 1

Cost 2 2 3 5 3 3

Mechanical

properties5 5 3 1 - 6

Near term

availability5 4 2 3 1 4

WP8 – Feasibility Studies

• Manufacturing feasibility assessment before material characterisation

• Simplified sub-element component designed with representative structural elements

• Over 40 articles moulded & 15 structurally tested

WP8 – Analysis Technique

• Analysis of random materials is difficult and no appropriate mainstream technology

exists yet

• Extensive empirical testing is expensive and the use of mean and standard deviation

values to generate allowables is generally prohibitive

• Engenuity are developing a series of test and analysis solutions that predict the

statistical failure populations with these materials

• Using this approach a higher degree of confidence is achieved and mass savings of

50% for some structures are projected

WP8 – Tooling & Press Arrangement

• Double impression tooling schemed

• Tool face detachment for part ejection

• Anticipate 6 to 8 minute cycle time

• 50+ articles to be produced

• Production scheduled early May

WP8 – Current Status

• Material testing nearly complete

• Preliminary geometry awaiting optimization

• Current DA design mass of 227g (circa 70% reduction)

• Economic target achievable but not met by selected material

WP11 – Low Speed Energy Absorber

• Links front crossmember with bumper

• Current part offers 40kN of resistance over 80mm

• Composite solution offers greater length of crush

• Existing mass 535g

• Target cost defined

WP11 – Partner Objectives & Exploitation

• SG objectives – to develop and integrate stamp forming activities with PtFS

• ENG objectives – to enhance analysis (CZONE) capabilities

• LMAT objectives – to demonstrate predictive capability for processed induced

distortion with thermoplastics

• EXTA objectives – to investigate & implement joining approach with TP composites

• Liberty Advanced Composites – Tier#1 representation

• Selected material; Tencate TC910 Cetex CF/PA6 unitape

Evaluation of, and compensation for,

process induced distortion by LMATStatic & dynamic testing at EngenuityWelding trials at Expert

WP11 – Demonstrator Solution

• Constant thickness stamp formed “organo sheet” solution

• Tooling surfaces compensated for distortion

• IR preheat of blank, manual loading, forming & rapid cooling

• Net, or near net, edge moulding

• Ultrasonically welded flange

• Projected mass 270g, 50% reduction

US welded flanges

Symmetric parts

Summary

• Significant achievements to date arising from the programme despite encountering

typical challenges

• Two clearly defined work packages will deliver fully tested demonstrator articles by

the end of May 2017

• Many exploitation opportunities have arisen through close partner collaboration

• A busy 3 months await….

Questions?

alasdair.ryder@surface-generation.com