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Rudolf Stauber Ludwig Vollrath (Eds.

Plastics in Automotive Engineering


Exterior Applications

Hanser Publishers, Munich Hanser Gardner Publications, Cincinnati

HANSER

Contents

Preface List of Contributors 1 Introduction to the Application of Plastics in Vehicle Design

V XIII 1

1.0 1.1 1.2 1.2.1 1.2.2 1.3


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Introduction Plastics in Lightweight Vehicle Engineering Plastics Applications for the Exterior Injection Molding with Polymers Textile-reinforced Plastics Outlook
Automotive Concepts and Lightweight Design

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2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7

Increased Use of Plastics in Body Applications: Opportunities and Risks Current Situation of Lightweight Materials Future Regulatory and Market Requirements Lightweight Construction for Rigid Components Use of Plastic as a Structural Material Competition Between Plastic and Stainless Steel Acoustics Summary Use of Plastics in Body Construction in Future Automobile Design and Production Introduction Structural Plastics The Body Tub Assembly SMC at Ford Motor Company Implications of the End of Life Vehicle Directive Summary Lightweight Design with Plastics in the New BMW 6 Series Material Mixture Saving Weight and Increasing Collision Safety Requirements for Thermoplastic Side Panels Criteria for the Use of a Thermoplastic Side Panel Material Requirements.. ~ Product Requirements for Component Design Manufacturing and Assembly Process Outlook and Future Requirements

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Contents

Material Concepts and Process Technologies

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3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4

Plastics Engineering in Automotive Exteriors Introduction History Processing Methods and Applications for Thermoplastics Processing Methods and Applications for Polyurethane Computer-Aided Engineering (CAE) Outlook Plastics for the Car of Tomorrow - Invisible Contribution: Visible Success Introduction Innovation Processes Making the "Invisible" Visible: Applying Nanotechnology Making the Virtual Real: Applied Simulation Technology CFRP - from Motor Sports to Automotive Series - Challenges and Opportunities Facing Technology Transfer Introduction CFRP at the Transition Between Motor Sports and Road Cars Current Applications of CFRP The Trends: a Closer Look Challenges Opportunities Outlook Further Developments in SMC Technology Reasons for Using SMC The Road to Premium SMC Lightweight Potential of SMC Technology Outlook for SMC Acknowledgements New TPO Grades with Reduced Linear Thermal Expansion for Exterior Parts Painted Offline Introduction Requirements and Basic Conditions Analysis and Simulation Techniques New TPO Grades and their Properties Compared with Other Technical Thermoplastics Component Test Results Lightweight Bodywork - Use of Structural Foams in Hollow Sections Introduction Requirements Applicable to Manufacture Selection of the Material System Process Conditions and Implementation

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59 59 59 59 61 61 64 65 68 68 68 70 74 74

75 75 75 77 78 80 82 82 83 84 87

Contents

3.6.5 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.9 3.9.1 3.9.2 3.9.3 4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5

Outlook Body-in-White turns Black Introduction FRP Manufacturing Technologies in the Mercedes-Benz SLR Mclaren Prepreg Technologies (Classical and RFI) Preform Technologies Summary Acknowledgements < Innovative Manufacturing Processes Adapted for the Production of Structural Modules Introduction The Evolution of Production Technologies for Structural Parts Developments of New Applications Future Potential of a New Process and Machine Technology Innovations in Injection Molding for the Automobile of the Future Introduction Innovative Areas for New Process Technologies Current Process Innovations in Injection Molding Modelling and Rapid Prototyping Innovative Solutions for Prototype-Making in Automobile Manufacturing Prototype Component Requirements and Practical Examples Passenger Car Development Prototype Requirements Selection of Suppliers Examples Summary Rapid Prototyping of Plastic Components for Efficient Vehicle Development Introduction The Importance of Rapid Prototyping Rapid Prototyping - a Definition Rapid Prototyping (RP), Rapid Tooling (RT), Rapid Manufacturing (RM): Some Differences The Prototype Assembly Department as Internal RP Service Provider Systems and Applications in the Prototype Assembly Department Outlook Calculating the Fatigue Life of Short-Glass-Fiber-Reinforced Thermoplastics Introduction Material Behavior under Cyclic Loading Formulation for Calculated-Fatigue Life Estimation Examples of Calculation Summary and Outlook

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123 123 125 129 129 133 135 135 135 136 138 138 140 142 143 143 143 145 147 151

Contents

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7
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Calculated Estimate of Service Life for Components Made of Short-glass-fiber-reinforced Plastics Introduction Initial Situation and Objectives Theoretical Considerations Procedure for Estimating Service Life Experimental Investigations Components and Component Tests Summary and Further Procedure Acknowledgments > Material Data for Imaging Thermoplastic Plastics in Crash Simulation Introduction Input Data for Crash Calculation Representation of Non-Linear Behavior in the Simulation Fiber-Reinforced Thermoplastics Validation of Material Data and Material Models Failure Analysis Outlook
Joining

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5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2

Bonded Joints in and on the Vehicle Structure Introduction Assembly Bonding Bonded Joints in and on the Body Testing, Development, Dimensioning Summary and Outlook Joining Techniques Used for Integrating Fiber Composite Plastic Components in Metallic Body Structures Introduction Lightweight Design Using Body Structures loining Techniques for Hybrid Aluminum-FRP Designs Study: Audi A2 with FRP Body Components Summary and Outlook
j'

173 173 173 175 178 180

181 181 181 182 189 190 192 192 195 197 197 198 198 198

Bonding Automotive Bodies Bonding - Often the Only Feasible Joining Technology New Adhesives for SMC Components Meet Maximum Requirements Chemical Thixotropic Adhesives Summary Warm Reactive Bonding , Headlight Bonding Current Status of the Technology

Contents

5.4.3 5.4.4 5.4.5 5.4.6 5.4.7


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Market Requirements and Wishes Just-in-Time Production Feasible Influence on Handling Strength Pump and Application System for Production Utilization in Series Production
Case Studies - Design, Production, Performance

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6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.4 6.4.1 6.4.2 6.4.3 6.5 6.5.1 6.5.2 6.5.3

Structures and Body Panels Case Study 1: Film Technology in Automobile Manufacturing - a Comparison Case Study 2: Hybrid Tailgate: Getting the Best From Thermosetting and Thermoplastic Materials Case Study 3: Experience with On-Line Paintable Plastics on Vehicle Exteriors Case Study 4: Application of Plastic Bodywork Components in a Modern Bus Case Study 5: Cab Body Panels and Parts: from Thermosets To Thermoplastics Front Modules, Crash Elements, Safety Concepts Case Study 6: Development of a Thermoplastic Lower Bumper Stiffener for Pedestrian Protection Case Study 7: Crash Simulation with Plastic Components Case Study 8: SLR Crash Element: from Concept to Volume Production Case Study 9: Thermoplastic Crashboxes Roof Modules, Hardtops Case Study 10: Roof Module: As Exemplified by the New Opel Zafira Case Study 11: The Z4 Hardtop Made of SMC - a Self-Supporting Automotive Part Made of Thermosetting Material in the Context of CARB Legislation Case Study 12: Innovative Noise-Optimized Folding Top for the New BMW 6 Series Convertible Case Study 13: Roof Module for Commercial Vehicles Made with SMI Technology Automotive Glazing Case Study 14: Organic Glazing in the Automobile Case Study 15: Polycarbonate Automobile Glazing: Automotive Industry Requirements and Solutions Case Study 16: Plastic Automobile Windows
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205 205 218 227 234 243 253 253 264 271 280 289 289 299 306 312 327 327 335 346 354 354 365 369
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Acoustics and Aerodynamics Case Study 17: Specific Requirements on Aeroacoustic Development for Convertibles Case Study 18: Automotive - Compression Molding - LWRT Technique for Car Underbody Covers Case Study 19: Noise-Reducing Coatings in Buses: the Mercedes-Benz Citaro

Appendix Subject Index

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