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Schuler SMG – the company

Application of vacuum-assisted high-pressure RTM-process for the series production of CFRP components for car bodies. Schuler SMG – the company. Schuler SMG is part of the Schuler Group The Schuler Group is the technological and world-market leader in forming technology

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Schuler SMG – the company

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  1. Application of vacuum-assisted high-pressure RTM-process for the series production of CFRP components for car bodies

  2. Schuler SMG – the company • Schuler SMG is part of the Schuler Group • The Schuler Group is the technological and world-market leader in forming technology • Schuler SMG is a system supplier for hydraulic presses and press lines with the brands SMG, Hydrap and Müller Weingarten • Employees Schuler SMG 2011/12: 666, of which 49 are apprentices

  3. Overview of presentation • Motivation for the use of CFRP parts in the automotive industry • The vacuum-assisted high pressure RTM press process • Press technology for the high pressure RTM process with example of supplied presses 36,000 kN – 3.6 x 2.4 m • System overview of complete RTM process • New development of press technology

  4. Light weight design in the automotive industry - Motivation Efficiency (environment) car Joy of driving Safety Future of mobility • Energy costs will rise • Fuel consumption and emmissions will be increasingly financially punished. • Laws concerning emissions influence mobility (E- mobility, etc.) • For development of new vehicles there is a challenge of balancing safety, efficiency (environment) and joy of driving

  5. Light weight design in the automotive industry - Potential Potential of various materials with regard to light weight design Steel Aluminum CFRP Quasi-isotropic CFRP unidirectional Source: Audi AG

  6. Overview of presentation • Motivation for the use of CFRP parts in automotive industry • The vacuum-assisted high pressure RTM press process • Press technologyforthe high pressure RTM processwithexampleofsuppliedpresses 36,000 kN – 3.6 x 2.4 m • System overviewofcomplete RTM process • New development of press technology

  7. Press processes for fiber reinforced plastic e.g. deck lid, bumper… e.g. spare wheel well, front end… e.g. passenger cell, roof… e.g. seat shell, front end… Source: BMW and BASF

  8. The vacuum assisted high pressure RTM press process Curing with compression force Preformplacement Resin injection, with position control Press closing, start apply vacuum Force up to 36.000 kN max. 80 barslide position +/- 0.05 mmforce up to 25.000 kN

  9. The vacuum assisted high pressure RTM press process Mold cleaning Mold opening Unload part Press opening Mold break open force Up to 5.000 kN

  10. Overview of presentation • Motivation for the use of CFRP parts in automotive industry • The vacuum-assisted high pressure RTM press process • Press technologyforthe high pressure RTM processwithexampleofsuppliedpresses 36,000 kN – 3.6 x 2.4 m • System overviewofcomplete RTM process • New development of press technology

  11. CFRP sample parts produced on Schuler presses • BMW i3 – passenger cell • BMW M3 – roof

  12. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  13. Requirements for the RTM press • Uniform wall thickness of the pressed part • Press statics with congruent bending lines of slide and table • Parallelism of slide to table also at high eccentric load

  14. Press design with congruent bending lines Design with congruent bending lines Traditional design Raising deviation of bending lines Wall thickness non-uniform Uniform wall thickness

  15. Press design with congruent bending lines • FEM optimized slide • Congruent bending lines lead to a flat slide construction

  16. Requirements for the RTM press • Uniform wall thickness of the pressed part • Press statics with congruent bending lines of slide and table • Parallelism of slide to table also at high eccentric load

  17. Hydraulic slide parallelism control • Eccentric load for the slide results from the process • Non-symmetric part geometry = eccentric center of force load • The liquid / pasty-like resin compound flows arbitrarily, when closing the mold Press frame Counter-acting parallelism control cylinders Mold Center of force load

  18. Hydraulic slide parallelism control • Four counter-acting cylinders • Each cylinder max. 2,000 kN / max. moment 8,000 / 4,000 kNm • Achievableparallelism: 0.05 mm absolute at 0.5 mm/s • Adjusting spindle for adaption of different mold heights (between 1,200 – 1,800 mm) • Parallelism cylinder with integrated position encoder

  19. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  20. Maintaining injection position of the slide • Task: • Maintaining of injection position against rising internal resin pressure and rising eccentrical load. Resin injection with slide position +/- 0.05 mm F at injection up to 25.000 kN • Solution: • Closed-loop control for position + parallelism with set value position of parallelism cylinders and actuating value slide force Cavity pressure max. 80 bar

  21. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  22. Design with 2 moving bolsters • Two lower molds and one shared upper mold • Part loading and unloading during the secondary processing time • Cleaning of the lower mold during the secondary processing time moving bolster 1 moving bolster 2 free position for bolster 2

  23. Design with two moving bolsters Telescopic cover for the bolster trench

  24. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  25. Smooth mold opening through parallelism control cylinders • Break-open of glued molds • Mold break open force up to 5.000 kN • Moving bolster locking device • Die clamps Example: turn-pull die clamps in slide and bolster Lock-pockets in the moving bolster • Locking bolts in the lateral upright

  26. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  27. Reliable media supply of molds Detail view media supply of upper mold automatic multi-couplings

  28. Requirements for the RTM press • Uniform wall thickness of the pressed part • Maintaining of resin injection position for gap-injection • Minimizing of non-productive time for mold cleaning / handling • Smooth mold opening • Reliable media supply to the molds • Short pressure build-up and efficient energy use

  29. Short pressure build-up time and efficient energy use • Accumulator drives • Charging pumps continuously charge with low power • Temporarily a high volume flow with nominal pressure is available for a working speed of 30 mm/s at 36.000 kN Charging pump units2 x 55 kWNoise < 75 dB(A)

  30. Overview of presentation • Motivation for the use of CFRP parts in automotive industry • The vacuum-assisted high pressure RTM press process • Press technologyforthe high pressure RTM processwithexampleofsuppliedpresses 36,000 kN – 3.6 x 2.4 m • System overviewofcomplete RTM process • New development of press technology

  31. System overview complete HP-RTM process From carbon fiber mats to a finished part HP-RTM Preforming Handling Stack production Material magazine Handling Trimming of finished part Heating Trimming of Fiber mats Mixture and dosage technology Trimming of preform

  32. System overview complete HP-RTM process Technology partners Schuler and Frimo Provision of garments Production of preform Trimming of preform Handling of preform RTM- press RTM-mold Mixing / Dosage technology Handling of cured part Machining of cured part

  33. Overview of presentation • Motivation for the use of CFRP parts in automotive industry • The vacuum-assisted high pressure RTM press process • Press technologyforthe high pressure RTM processwithexampleofsuppliedpresses 36,000 kN – 3.6 x 2.4 m • System overviewofcomplete RTM process • New developmentof press technology

  34. Short stroke press – Function principle slide mold press plate - Slide starts moving downwards (parallelism controlled) - Working stroke with press plate from bottom - Slide is locked by split nuts - Press plate starts movement upwards (parallelism controlled) - Slide reached working position 1 3 4 2

  35. Short stroke press – Parallelism control • Individual setting of press force between cylinders • Parallelism control integrated • Bending line of press table can be influenced • Congruent bending lines of press table and slide • Two central positioned cylinders • Four edge-positioned cylinders

  36. Short stroke press – Technical innovation • Reduction of machine height • Easy accessibility • Integrated parallelism control • Short pressure build up time • Reduced energy consumption

  37. Thank you very much for your attention We are looking forward to your visit at our booth

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