Next Generation of Automotive Crossmember by cOMlding Epoxy SMC with Fibre Steered Preforms (GACOM)

通过将环氧 SMC 与纤维转向预成型件 (GACOM) 混合来制造下一代汽车横梁

• 批准号: 10081994
• 金额: $ 32.78万
• 依托单位: ICOMAT
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2023
• 资助国家: 英国
• 起止时间: 2023 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=10081994
• 关键词: Next; Generation; Automotive; Crossmember; cOMlding

Green mobility is key for a Net-Zero future. Composites are a critical enabler to deliver lightweight solutions with ultimate performance. However, current manufacturing technologies are costly and inherently slow as well as limited in terms of fibre orientation distribution, given that current deposition and laying-up solutions force straight/geodesic continuous fibre-paths. These issues result in labour-intensive and prolonged manufacturing processes with low-productivity, increased energy consumption, production costs and environmental footprint, hindering wide adoption of composites in automotive.iCOMAT has developed the Rapid Tow Shearing (RTS) process, an innovative composites automated deposition process which deposits wide composite tapes along curved-paths (fibre-steering) without generating defects. RTS's steering capabilities offer tremendous benefits in terms structural performance, weight, production costs and environmental footprint.GACOM is a 24-month collaborative project aiming to deliver the new state-of-the-art in the manufacture of hybrid SMC/UD composite components used in automotive applications. GACOM builds on the skeleton/flesh concept which was successfully demonstrated during LeAFS-SBRI-10004512\. The skeleton/flesh concept includes the use of low-cost/low performance Sheet-Compound-Moulding (SMC) ''flesh'' material strategically reinforced with structural unidirectional (UD) carbon-fibre tapes acting as a ''skeleton''. This is enabled by RTS's unprecedented steering capabilities.GACOM will be led by iCOMAT with Hangukmold and KCarbon as project partners. Hangukmold is a world-leading expert in the manufacturing of commercial vehicle composite parts and is an existing Tier1 supplier of OEMs such as Hyundai and KIA among others. KCarbon is a South-Korean Research-Institute specialising in material characterisation and composites manufacture.GACOM will utilise the skeleton/flesh concept to manufacture and validate a hybrid SMC/UD front car crossmember. GACOM's activities include:* Component optimisation using Finite Element (FE) structural models* manufacture a full-­scale fibre-steered hybrid SMC/UD front car crossmember (lower/upper)* quantify the performance, light-weighting and economic benefits of the developed technology and further develop the business caseGACOM will demonstrate that high­-quality automotive components can be manufactured using RTS, delivering the new state­-of­-the-­art in automotive composites manufacture. This will result in innovative next generation crossmembers that are closer to the structural-optimum (lighter with same performance), use less raw material, and are manufactured faster/cheaper than the current state­-of-­the-­art.Overall, successful completion of GACOM will drastically boost iCOMAT's presence in automotive and place the UK at the driver's seat of advanced manufacturing of automotive composite components.

绿色出行是实现零净未来的关键，是提供具有终极性能的轻量化解决方案的关键推动者。然而，考虑到当前的沉积和纤维取向分布，当前的制造技术成本高昂，本质上速度缓慢，而且在纤维取向分布方面也受到限制。铺设解决方案迫使采用直线/测地连续纤维路径。这些问题导致制造过程耗时长、生产率低、能源消耗增加、生产成本增加和环境足迹增加，阻碍了复合材料在汽车领域的广泛采用。这快速丝束剪切 (RTS) 工艺是一种创新的复合材料自动沉积工艺，可沿弯曲路径（纤维导向）沉积宽幅复合材料带，而不会产生缺陷，RTS 的导向功能在结构性能、重量、生产成本和环境足迹方面提供了巨大的优势。 .GACOM 是一个为期 24 个月的合作项目，旨在提供汽车应用中使用的混合 SMC/UD 复合材料部件的最新最先进技术，GACOM 建立在骨架/肉体概念的基础上。在LeAFS-SBRI-10004512期间成功演示了骨架/肉体概念包括使用低成本/低性能片状复合成型（SMC）“肉体”材料，并通过结构单向（UD）碳纤维进行战略性增强。磁带充当“骨架”。这是由 RTS 前所未有的控制能力实现的。GACOM 将由 iCOMAT 领导，Hangukmold 和 KCarbon 作为项目合作伙伴。 Hangukmold 是世界领先的商用车复合材料零件制造专家，也是现代和起亚等 OEM 的现有一级供应商。 KCarbon 是一家专门从事材料表征和复合材料制造的韩国研究所。利用骨架/肉体概念来制造和验证混合 SMC/UD 前车横梁 GACOM 的活动包括：* 使用有限元 (FE) 结构模型进行组件优化* 制造一个。全尺寸纤维转向混合 SMC/UD 汽车前横梁（下/上）* 量化所开发技术的性能、轻量化和经济效益，并进一步开发业务案例 GACOM 将证明可以制造高质量的汽车零部件使用 RTS，提供最先进的汽车复合材料制造技术，这将带来更接近结构优化（更轻且性能相同）、使用更少原材料且制造速度更快的创新型下一代横梁。 /更便宜总体而言，GACOM 的成功竣工将极大地提升 iCOMAT 在汽车领域的影响力，并使英国成为汽车复合材料部件先进制造领域的主导者。