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.

绿色移动性是净零未来的关键。复合材料是至关重要的推动力，可以提供具有最终性能的轻量级解决方案。但是，鉴于当前的沉积和铺设溶液强力直/地球连续纤维径，当前的制造技术在纤维方向分布方面的质量高昂，固有的速度较慢，并且在纤维方向分布方面却有限。这些问题导致劳动密集型和延长的制造过程，其生产率低，能源消耗增加，生产成本和环境足迹，妨碍了自动化中的合成的广泛采用。ICOMAT开发了快速拖曳剪切（RTS）工艺，一种创新的组成构成工艺，该过程沉积了沿曲线范围宽阔的组合胶带，而没有沿曲面的组合胶带（Fibre-Paths）（fibre paths）。 RTS的转向能力在结构性性能，重量，生产成本和环境足迹方面提供了巨大的好处。GACOM是一个24个月的协作项目，旨在提供用于自动动力应用中使用的混合SMC/UD复合组件的新最新艺术。 GACOM建立在骨骼/肉概念上，该概念在Leafs-Sbri-10004512 \中成功证明。骨骼/肉概念包括使用低成本/低性能板混合摩尔德（SMC）''''''''''''''用结构性单向（UD）碳纤维胶带策略性地加固，用作“ Skeleton”'。这是由RTS前所未有的转向能力来启用的。GACOM将由ICOMAT领导，Hangukmold和Kcarbon是项目合作伙伴。 Hangukmold是商用车复合零件制造的世界领先的专家，并且是现有的OEM的Tier1 Tier1供应商，例如现代和起亚等。 KCARBON是一家南部研究所的研究所，专门从事材料表征和制造成分。Gacom将利用骨架/肉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）结构模型的组件优化*制造全尺度的纤维式混合SMC/UD前车越野越过（下/上）汽车组件制造。这将导致创新的下一代交叉成员更接近结构性优势（表现相同），使用较少的原材料，并且制造的速度较低，并且比当前的最新制度更快/更便宜。