Increasing current and future demands for the reduction of vehicle weight, reducing exhaust emissions and fuel usage, is driving the need for cost effective composite material processing techniques. To assess the potential of using composite materials in automotive body-in-white (BIW) structures beyond niche vehicles, the cost potential of two resin transfer moulding (RTM) processes have been examined using technical cost modelling (TCM) tools. The conventional epoxy thermoset system has been compared with a novel reactive PA12 system. Carbon fibre reinforcement has been used to achieve the required weight specific stiffness versus steel. Based upon manufacturing cells optimised for complex shapes and middle volume production, the two RTM variants have been compared for the floor-pan of a BIW structure. The TCM model was used to extrapolate from the current state of the art what effect changes to the reactive PA12 material system chemistry, impregnation time, and tooling technology would have on part cost. Implementation of any such material system would have wide ranging effects on the automotive supply chain, and this is illustrated with a discussion of dedicated and utilisation based part costs and the strategic issues involved with such an implementation step.
Manufacturing cost comparison of thermoplastic and thermoset RTM for an automotive floor-pan
Fertigungskostenvergleich des thermoplastischen und duroplastischen Harzspritzpressens für eine Kraftfahrzeug-Bodenwanne
2004
6 Seiten, 7 Bilder, 1 Tabelle, 7 Quellen
Conference paper
English