The Hybrid Compression Moulding of Structural Composite Materials for Automotive Applications

Helena C. Simmonds; Neil C. Reynolds; Kenneth N. Kendall

doi:10.4028/www.scientific.net/KEM.843.3

Paper Titles

The Hybrid Compression Moulding of Structural Composite Materials for Automotive Applications
p.3

Direct Polymer Additive Tooling - Economic Analysis of Additive Manufacturing Technologies for Fabrication of Polymer Tools for Injection Molding
p.9

On the Effect of Material Properties Uncertainty on the Magnitude of Temperature Oscillations in Two-Component Periodic Laminate: Tolerance Averaging Modelling
p.19

Printability Analysis of Compostable Films by Flexographic Water Based Ink
p.26

Evaluation of the Mechanical Properties of Carbon Nanotube (CNT) Reinforced Aluminum (6061) Composites Using Closed Die Forging
p.33

Real-Time and In Situ Monitoring of FRP by Rayleigh Scattering-Based Distributed Sensing
p.39

Comparison of Degradation and Recovery of SiON_x and Hf-Based Dielectric under Electrical-Field Stress
p.47

Progress in Creation of a New Constant Medium for Hyperpolarized MRI
p.52

HomeKey Engineering MaterialsKey Engineering Materials Vol. 843The Hybrid Compression Moulding of Structural...

The Hybrid Compression Moulding of Structural Composite Materials for Automotive Applications

Abstract:

The Innovate-UK-funded Composite Lightweight Automotive Suspension System (CLASS) project, led by Ford Motor Company and partnered by Gestamp UK, GRM Consulting and WMG, investigated the use of carbon fibre reinforced composite materials to decrease the weight of a complex automotive rear suspension component in support of reduction in vehicle emissions. A multi-material design comprising discontinuous fibre composite (C-SMC), aligned fibre composite laminate (prepreg) and steel was developed. A high volume hybrid compression moulding manufacturing process was developed at WMG, achieving total press cycle times of around 5 minutes. Prototype parts were manufactured and evaluated using materials characterisation techniques to validate the manufacturing methods. The optimum C-SMC charge pattern was investigated to achieve complete fill with minimal pre-processing. Destructive and nondestructive analysis of the hybrid parts was performed to understand resultant hybrid material macrostructure. This innovative design and manufacturing process resulted in a component 35% lighter than the original multi-piece steel design.

You might also be interested in these eBooks

Congress on Advanced Materials Sciences and Engineering

View Preview

Info:

Periodical:

Key Engineering Materials (Volume 843)

Pages:

3-8

DOI:

https://doi.org/10.4028/www.scientific.net/KEM.843.3

Citation:

Cite this paper

Online since:

May 2020

Authors:

Helena C. Simmonds*, Neil C. Reynolds, Kenneth N. Kendall

Keywords:

Composites, Compression Moulding, Prepreg Compression Moulding, SMC

Export:

RIS, BibTeX

Price:

Permissions CCC:

Request Permissions

Permissions PLS:

Request Permissions

Сopyright:

Citation:

* - Corresponding Author

References

[1] Banks, A.J., Composite Lightweight Automotive Suspension System (CLASS). 2019, SAE International.

Google Scholar

[2] Melotik, D.J., et al., Analysis of the resin transfer molding process using in-mold dielectric sensors. Thermochimica Acta, 1993. 217: pp.251-262.

DOI: 10.1016/0040-6031(93)85114-o

Google Scholar

[3] Launikitis, M.B., Vinyl Ester Resins, in Handbook of Composites, G. Lubin, Editor. 1982, Springer US: Boston, MA. pp.38-49.

DOI: 10.1007/978-1-4615-7139-1_3

Google Scholar

[4] Kendall, K.N., et al., Characterization of the resin transfer moulding process. Composites Manufacturing, 1992. 3(4): pp.235-249.

DOI: 10.1016/0956-7143(92)90111-7

Google Scholar

[5] Yang, Y., et al., Development of a Dielectric Sensor System for the On-line Cure Monitoring of Composites. Procedia Technology, 2014. 15: pp.631-637.

DOI: 10.1016/j.protcy.2014.09.024

Google Scholar