Coe For Automotive Plastics: White Paper

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White Paper

________________
________
CoE for Automotive
Plastics
Version: DRAFT
Release Date: 13.06.2018
Contents
1. Introduction...........................................................................................................3
1.1. Purpose..........................................................................................................3
1.1.1. What are we trying to do?...........................................................................3
1.1.2. Problem being Addressed..........................................................................3
1.1.3. Market Opportunities.................................................................................. 3
1.1.4. Customer Problems....................................................................................3
1.1.5. Future Needs..............................................................................................3
2. The Concept - CoE...............................................................................................4
2.1. Scope.............................................................................................................4
2.2. Value Creation – Customer............................................................................4
2.3. Value Creation – Industry...............................................................................4
2.4. Value Creation – Self.....................................................................................4
2.5. Efficiency Improvements - Technology Use...................................................4
2.6. Efficiency Improvements - Statistical Use......................................................4
2.7. Efficiency Improvements - R&D facilities.......................................................4
2.8. Efficiency Improvements - Innovations..........................................................4
3. Business Case......................................................................................................5
3.1. Market............................................................................................................5
3.2. Market Size....................................................................................................5
3.3. Geography..................................................................................................... 5
3.4. Service Offerings........................................................................................... 5
3.5. Break Even Analysis......................................................................................5
3.6. Growth Strategy.............................................................................................5
4. Roadmap to Excellence........................................................................................6
4.1. Initial: Pilot Project........................................................................................ 6
4.1.1. Identify and define People, Process, Technology.......................................6
4.1.2. Identify Roles, Cycle Time, Deliverables....................................................6
4.2. Growth: Local Market.....................................................................................6
4.2.1. Expand and refine People, Process, Technology.......................................6
4.2.2. Refine Roles, Cycle Time, Deliverables......................................................6
4.3. Excellence: Global Market.............................................................................6
1. Introduction
Polypropylene (32%), polyurethane (17%) and polyvinyl chloride (16%) are the top 3
polymers being used in the automotive sector. ABS and Polycarbonates are the
other major plastics being used in automobiles.
Plastics are currently extensively used in the interior of the vehicles from dashboard,
instrumentation panel, seating among others. Its flexibility allows manufacturers to
create innovative single piece design which are light weight. It also helps in noise
reduction and covering vibration. These advantages not only drive costs down but
also help saves time during assembly. As a result more than 50% of car interiors are
now made of plastics.
Indian government has put in place stringent norms for improving fuel efficiency in
April 2014. The new standards are called Corporate Average Fuel Consumption
(CAFC) standard. The Indian government has set a target of 14-percent increase in
fuel mileage by 2016/17. Regulation gets even more stringent with a 38% increase in
fuel efficiency by 2021/22. Indian OEMs are considering light weighting as one of
levers to improve fuel efficiency. Also, the fuel emission norms will get more stringent
as India will jump directly from BS IV to BS VI (equivalent of Euro VI) which will come
in place in April 2020.

Plastic play a key role in improving fuel efficiency and lower emission by reducing
the weight of vehicle. 1 Kg of plastic can typically replace 2-3 Kg of traditional
materials in a vehicle. And typically, 100Kg reduction in weight can save 0.3-0.4 Litre
of fuel on a distance of 100 Km, as per the Europe commission report on light-
weighting.
Even globally, 65% of automakers, as per the Wards Auto 2016 Survey, are
considering light-weighting as an option to meet the CAFE (global equivalent of
CAFC) 2025 targets. Automakers are however only moderately confident about
existing materials to meet the requirements. Engineered plastics are among the top
choices along with Aluminium and mixed materials.
Indian government has mandated automakers to undergo frontal and side crash test
for their new vehicles from 2017. Plastics, because of their impact absorption
capability are being increasing used in parts as shock absorbers for bumpers, air
bags and side impact protection. Several automakers are using impact resistant
plastics in side doors to provide safety in side-on crashes. Plastics are also used for
fuel tanks as they are seamless and less prone to failures during accidents.
Overall automotive design (interior & exterior) is one of key determinant of vehicle
purchase among other consideration such as price, brand, and fuel economy. It is
also one of the ways to differentiate in the market. As a result, automakers continue
to innovate on design. Plastics’ versatility allow innovative shapes, design, styling
and forms vis-à-vis metals. For example, design of single unit front fascia, at low
cost, is difficult using metal as input. While lending versatility, plastics don’t
compromise on safety, comfort or stability of a car. It offers better protection against
corrosion than metals and improves lifespan of vehicle. It also allows engineers to
combine several parts into one (creating modules) which are cost effective and easy
to assemble.
CAR’s Coalition for Automotive Light weighting Materials (CALM) group identified material
qualification as one of the major barriers to faster introduction of lightweight materials in an
automobile along with other barriers such as joining technology, traditional paint-shops,
availability of simulation tools, and global supply-chain.

1.1. Purpose
The purpose of this whitepaper is to highlight opportunities to reduce the material
qualification barrier, availability of simulation tools, and global supply-chain for faster
introduction of advanced light weighting plastics.
Polypropylene by virtue of being the lightest thermoplastic material with extensively
wide range of properties achievable takes the lead sit in the light weighting segment.

1.1.1.What are we trying to do?


o Obtain direction and awareness into the manufacturing process to
optimize the part and injection molding process design.
o Achieve precision through comprehensive material data and process
performance customization.
o Also the activities are addressing to troubleshoot mold design in terms
of suggestions of gating, runner balance etc.

1.1.2.Problem being addressed


 Filling Analysis
 Gate location analysis
 Moulding Window analysis
 Sink Mark analysis
 Geometry Analysis
 Cooling quality analysis
 Runner balancing analysis
 Runner adviser Analysis
 Cooling analysis
 Packing Analysis
 Warpage Analysis
 Structural analysis
In general any analysis covers most of the things presented above. The analysis
sequence is presented below.

Part Finite Element Analysis (Indicates quality of the part CAD cesign) => Gate
location analysis => Molding window analysis => Cooling analysis => Runner
Balancing => Fill-Pack-Warp Analysis.
The complete analysis suggests complete behaviour of the material for the molding
process for a given part geometry. Two examples of complete analysis report is
attached for reference.
2. Mold Flow analysis of Jeep-Y series front grill.
3. Mold Flow Analysis of Front Loading Washing Machine Tub, Base Plate.

3.1.1.Market Opportunities
3.1.2.Customer Problems
3.1.3.Future Needs
4. The Concept – CoE

4.1. Scope

Mold flow analysis (or MFA) uses software to create a simulation of plastic flow,
allowing manufacturers to enhance the design of their mold and create a better
product.
By conducting mold flow analysis, manufacturers can get a glimpse into how the
material they are using will fill the cavity of a mold, and spot possible problems.
Creating a virtual version of the mold before the physical cutting begins allows you to
make changes and save on production costs.
Every part analyzed has a different set of constraints in the form of objectives,
restrictions, and guidelines. These constraints are taken into consideration when
completing an analysis. The objectives defined for a part are as varied as the parts
that can be injection molded. Below is a list of analysis objectives that you could
have. Some are just flow analysis related; others will require cooling and warpage
analysis. Having a clear understanding of the analysis objectives is one of the most
important steps and is a key factor regarding which analysis product is to be used.

4.2. Value Creation – Customer

The benefits of using mold flow analysis include:


1. It allows us to resolve wall thickness issues.
2. MFA lets us fill cavities in molds with consistency.
3. We can unearth faults in design geometry, and avoid expensive tooling errors.
It also gives us more support if you need to make a case for design changes
to your client.
4. We’ll improve manufacturability, improve quality and efficiency and reduce
time to market.
Mold flow analysis lets user uncover visual defects such as air traps, weld lines, and
sink marks, and allows you to optimize gate location.
Another key benefit is using the program to predict generalized molding parameters
allowing for efficient set-up during the trial phase.
”A most common customer concern is gate location, many surface areas are
cosmetic, on which a gate blemish cannot be tolerated, ” says John Burk, Mars’
Tool Engineering Manager, and moving a gate after mold construction is, at
maximum costly, if not impossible.”
4.3. Value Creation – Industry

MFA benefits the Industry in multitude ways due to the activities and forecasting of
potential behaviour as well as application-part geometry-mold-molding process-
material combination. Among the many possible objectives:

1. Will the part fill?


2. What material will work best for the part with regards to fill properties, i.e.
pressure, shear stress, temperature distribution, etc.?
3. What processing conditions should be used to mold this part?
4. Where should the gate be located?
5. How many gates are required?
6. Where will the weld lines be, and will they be of high quality?
7. Will there be any air traps?
8. How thin can the part be made?
9. Is the flow balanced within the part with the fixed gate location?
10. Are ribs too thin to fill completely?
11. Are ribs so thick that they shrink too much?
12. Can the part be packed out well enough?
13. Will this snap fit break during use?
14. Can the part be filled and packed in the press specified for the job?
15. Are the runners balanced?
16. What size do the runners need to be to balance the fill?
17. Is the runner volume as small as it can be?
18. Is the gate too big or too small?

4.4. Value Creation – Self

In terms of self value creation MFA unfolds a totally new area of research to a
polymer scientist/ engineer/ problem investigator/ support personnel. There are
multiple benefits to MFA. They include:
1. Resolution of wall thickness complications
2. Gate location optimization
3. Mold cavities fill consistently and uniformly
4. Discover defects in design geometry
5. Prevent expensive tooling errors and rework
6. Enhance manufacturability
7. Reduce time to market
8. Boost efficiency and quality
9. Reveals potential visual defects, including air traps, sink marks and weld lines
10. Assess different material options, pre-production
11. Provides data to support design changes
4.5. Efficiency Improvements - Technology Use

The secret to a quality plastic injection molded part is a flawless mold – one that
produces consistent pieces time and time again. So, what's the key to a flawless
mold? In addition to a strong initial design, mold flow analysis is your secret weapon.
It's an indispensable component of any plastic injection molding design project. MFA
software comes at a cost, but its impact on mold quality, product performance and
appearance, and production ROI is undeniable. Read on to learn how this one tool
can literally save your mold design.

4.6. Efficiency Improvements - Statistical Use


4.7. Efficiency Improvements - R&D facilities
4.8. Efficiency Improvements - Innovations
5. Business Case
5.1. Market
5.2. Market Size
5.3. Geography
5.4. Service Offerings
5.5. Break Even Analysis
5.6. Growth Strategy
6. Roadmap to Excellence
6.1. Initial: Pilot Project

Quite a good number of pilot projects are done. Two examples of pilot projects are attached
for reference.
1. Jeep-Y Series Front Grill.
2. Washing Machine Tub, base Plate.

6.1.1.Identify and define People, Process, Technology


6.1.2.Identify Roles, Cycle Time, Deliverables
6.2. Growth: Local Market
6.2.1.Expand and refine People, Process, Technology
6.2.2.Refine Roles, Cycle Time, Deliverables
6.3. Excellence: Global Market

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