Liquid Compression Molding (LCM) Technology for Mass ... · Liquid Compression Molding (LCM)...
Transcript of Liquid Compression Molding (LCM) Technology for Mass ... · Liquid Compression Molding (LCM)...
Liquid Compression Molding (LCM) Technology for Mass Production of Continuous Fiber Composite Epoxy Matrix Components Stephen Greydanus, Cedric Ball, Ian Swentek– Hexion Thomas Jaeger – Alpex Technologies Erich Fries – Krauss Maffei
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The car industry implements light weight solutions to comply with CO2 emission and fuel consumption reduction legislation
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How can we achieve a potential weight reduction of 70% at competitive part cost
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Source: Roland Berger
400 kg
320 kg
240 kg 200
kg 160 kg 120
kg
Current steel Optimised steel Aluminium Magnesium CFRP today CFRP ?
100%
-10 -20%
-40% -50%
-60% -70%?
Relative cost
50% material • 40 - 45% carbon fiber • 5 - 10% resin
50% processing • Quicker curing matrix • Process optimization • Near-end-contoured preforms • Automation
CFRP Epoxy Composites
Optimum CFRP performance and cost is complemented with good design
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Process Capability For OEM Industrialization
Materials Partnerships
Through Value Chain
Optimum Performance
and Cost
Liquid Resins Hot Melts Perform Binders Mould Release Agents
Prototyping Systems
Injection Moulding LCM Prepreg HP-RTM
Preforming SMC FiWi Towpreg
Equipment Suppliers Part Design and Modeling Process Design and Modeling Tool Fabrication
Reinforcements
Complimentary Manufacturing Processes: Resin Transfer Moulding (RTM) and Liquid Compression Moulding (LCM)
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Robust process technologies for rapid manufacturing of continuous fiber composites
Compatible for range of simple to complex part geometries
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HP-RTM Process Overview In the HP-RTM process, resin is injected into the fabric preform in closed matched metal tooling in a compression press
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Cycle time is driven by number of factors:
Press and injection equipment Part size and complexity Resin type and quantity Injection flow rate (driven by geometry and preform
permeability)
Preform tool Binder
Stabilized Fabrics
Press Injection Curing Opening & de-moulding
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LCM Process Overview
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In the LCM process, the resin is applied to the top of the fabric, either outside or inside the open tool cavity. The press then closes and resin is pressed into the laminate, primarily in ‘z’ direction
Liquid resin application
Transfer wet lay-up into
mould
Curing
Opening & de-moulding
Fiber preparation
Process and Cycle Time Advantages: Preforming not required for majority of compatible parts –
removing process step Faster impregnation of fiber than with RTM injection
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LCM cycle times of 50 seconds have been demonstrated
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Press closing
Impregnation
Curing
Press opening
LCM Moulding Tool - Cross Section
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Resin Pre-applied to Fiber Stack
Arrows showing direction of impregnation during mold closure
Upper Mould Tool
Lower Mould Tool
Fabric Stack
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Both RTM and LCM require technical expertise and process development
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RTM LCM
Resin Flow/Fiber Impregnation (during Injection)
Resin Flow/Fiber Impregnation (during Mold Closure)
Liquid Compression Molding (LCM) is cost attractive with increasing complexity of parts
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Low Part complexity
Cos
t Pr
efor
m re
quire
men
ts
Proc
ess
com
plex
ity
High
High
RTM
LCM
Considerations to compare for CFRP part cost
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Process RTM High Pressure - RTM LCM
Injection rate (g/s) 40 100 100
Process temperature (°C) 120 120 140
Cavity pressure (bar) 15 80 30
Required injection time (s) 60 24 N.A.
Tool cycle time (s) 360 93 50
Injection equipment 3K RTM 3K HP-RTM 3K RTM
Press (ton) 500 2.500 1.000
Tooling cost Relative x1.5 x2 1
Build rate pc/year 20.000 70.000 120.000
Fixed tooling cost/part Relative x11 x4 1
Dimensions : 1500 mm x 1200 mm x 3mm Volume (cm3) : 5.400 Resin amount (g) : 2.400
Example Part -
The part size and equipment determine the material processing window
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Part
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100 120
Resin Injection rate (g / sec) 60 g/s
Injection time (sec)
Resin Shot weight (g)
EP TRAC 06170 EK TRAC 06170
33 sec
EP TRAC 06150 EK TRAC 06165
45 sec
EP TRAC 06150 EK TRAC 06150
95 sec
80 g/s 100 g/s
80% of Moulded parts
Equipment
Material
The BMW 7-Series Carbon Core illustrates body-in-white mixed material use
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BMW 7-Series Various CFRP parts e.g. roof arc and tunnel reinforcement BMW SOP: 2015
Source: BMW Group
Benefits • 40 kg weight reduction vs. steel in the Carbon Core body structure • Fast curing cycle enabled by Hexion latest resin technology • Multi material mix – engineered to performance
Applications - Epoxy CFRP LCM & RTM technology for structural applications
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BMW 7-Series CFRP roof arc EP TRAC 06000/ EK TRAC 06130
Benefits • Local reinforcement enhances
torsional stiffness
BMW 7-Series CFRP tunnel reinforcement EP TRAC 06000/ EK TRAC 06130
Benefits • Designed to the shape of the car body • Fast curing cycle with HP-RTM • Outstanding weight / performance ratio
Complex part geometry requires HP-RTM process
Simple geometry of part is compatible with LCM process
Key Takeaways
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Liquid Compression Molding (LCM): Complimentary moulding process to HP-RTM for molding simple to complex geometry composite parts
Key LCM process benefits: Fastest process technology for manufacturing continuous fiber composites today – Cycle times less than 90 seconds
Cost competitive: Robust processing and rapid cycle time for LCM manufacturing makes Epoxy CFRP increasingly competitive as a lightweighting technology
Thank you!
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Stephen Greydanus Automotive AD and TS Manager NA [email protected]
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