1、Plastics Application Technology for Safe and Lightweight Automobiles Sudhakar R. Marur Plastics Application Technology for Safe and Lightweight Automobiles Sudhakar R. Marur This book focuses on using plastics in automobiles for traditional applications such as interiors and body panels, and for mor
2、e advanced applications such as glazing and under-the-hood components. It provides application technology development for various aspects of automotive designconcept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making. It i
3、s based on a decade of research and real-world application of the authors. Described are design and manufacturing aspects of energy absorbers, fenders, front-end modules, instrument panels, steering wheels, headlamp assemblies, throttle bodies, glazing, and tailgates, as well as exterior components
4、such as roof racks, wipers, door handles, and rearview mirror assemblies. Using engineering thermoplastics for such applications will improve safety and reduce the weight of next-generation automobiles. Readers will gain an understanding of design and manufacturing methodologies of plastics and the
5、means to apply them to a particular vehicle platform. The intent is to help further engineering expertise about using plastics in automobiles so that they can be safer, lighter, and more energy efficient. About the Editor Sudhakar R. Marur led the plastics application technology laboratory, as its t
6、echnical director, for SABIC Innovative Plastics in Bangalore, India. Under his leadership, the team developed plastics application solutions for automotive companies worldwide. He has more than 23 years of experience in industrial R phone 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside
7、 U.S. and Canada); fax 724-776-0790; email CustomerServicesae.org; website http:/ /books.sae.org. 6351_Book.indb 2 7/9/13 11:17 AMPlastics Application Technology for Safe and Lightweight Automobiles Edited by Sudhakar R. Marur Warrendale, Pennsylvania, USA 6351_Book.indb 3 7/9/13 11:17 AM Copyright
8、2013 SAE International eISBN: 978-0-7680-8018-6 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-0790 Copyright 2013 SAE International. All rights reserved. No part of this publicat
9、ion may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; email: copyrightsae.org; p
10、hone: 724-772-4028; fax: 724-772-9765. ISBN 978-0-7680-7640-0 SAE Order Number R-415 DOI 10.4271/R-415 Library of Congress Cataloging-in-Publication Data Marur, Sudhakar R.Plastics application technology for safe and lightweight automobiles / by Sudhakar R. Marur.pages cm“SAE order number R-415”Titl
11、e page verso.Includes bibliographical references.ISBN 978-0-7680-7640-01. Plastics in automobiles. 2. AutomobilesSafety measures. 3. Lightweight materials. 4. Reinforced plastics. I. Title. TL240.5.P42S27 2013629.232dc23 2013016403 Information contained in this work has been obtained by SAE Internat
12、ional from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of thi
13、s information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. T
14、o purchase bulk quantities, please contact: SAE Customer Service Email: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-0790 Visit the SAE International Bookstore at books.sae.org Illustrations credit: P. Arunachala, Front cover illustration
15、: B. Deshmukh 6351_CH00.indd 4 8/9/13 3:59 PMDedication The late Dr. Wim Bruijs Director, Application TechnologyEurope SABIC Innovative Plastics Bergen op Zoom The Netherlands 6351_Book.indb 5 7/9/13 11:17 AM6351_Book.indb 6 7/9/13 11:17 AMvii Table of Contents Preface .xv Chapter 1 Introduction to
16、Plastics Application Technology . 1 1.1 Introduction .1 1.2 Application Development Cycle 2 1.2.1 Voice of the Customer .2 1.2.2 Benchmarking .2 1.2.3 Material Selection.2 1.2.4 Styling and Industrial Design 3 1.2.5 Computer-Aided Design 3 1.2.6 Computer-Aided Engineering 3 1.2.7 Process Modeling.3
17、1.2.8 Tooling3 1.2.9 Prototyping 4 1.2.10 Secondary Operations .4 1.2.11 Part Testing 4 1.3 Material Selection Methodology 4 1.3.1 Screening of Material Properties 4 1.3.2 Conversion Processes .5 1.3.3 Structural Requirements .5 1.3.4 Environmental Conditions .5 1.3.5 Assembly and Secondary Operatio
18、ns5 1.3.6 Cost Factors5 1.3.7 Regulations and Standards Compliance .5 1.4 Advantages of Plastics 6 1.4.1 Styling Freedom 6 1.4.2 Material Property.6 1.4.3 Performance .6 1.4.4 Part Integration 7 1.4.5 Weight Reduction.7 1.4.6 System-Level Cost Reduction 7 1.5 Key Automotive Plastics Applications .7
19、1.5.1 Safety and Energy Management 7 1.5.2 Interiors and Occupant Safety 8 1.5.3 Glazing 11 6351_Book.indb 7 7/9/13 11:17 AMviii Table of Contents 1.5.4 Plastic-Metal Hybrid Structures .12 1.5.5 Headlamps .13 1.5.6 Body Panels.14 1.5.7 Under-the-Hood Components.15 1.6 Summary.17 1.7 References 17 Ch
20、apter 2 Crash and Energy Management Systems . 23 2.1 Introduction 23 2.2 Safety as an Emerging Global Concern .25 2.3 Regulatory and New Car Assessment Program Crash Test Requirements .25 2.3.1 Pedestrian Impact Tests.26 2.3.2 Low-Speed Vehicle Damageability or Bumper Structural Tests 27 2.3.3 High-
21、Speed Crashes for Occupant Protection28 2.4 Impact and Energy-Absorption Efficiency.29 2.5 Design of Energy-Absorbing Elements .32 2.6 Pedestrian Protection 33 2.6.1 Vehicle Bumper Stiffness Profile .33 2.6.2 Design of Pedestrian-Safe Bumper Systems .36 2.6.3 Pedestrian Energy Absorbers43 2.6.3.1 Pe
22、destrian Energy AbsorbersMiddle Load Path .43 2.6.3.2 SUV Energy AbsorbersUpper Load Path 47 2.6.3.3 UndertrayLower Load Path .49 2.7 Countermeasures for Low-Speed Vehicle Damageability Tests51 2.7.1 Bumper Design Challenges .51 2.7.2 Thermoplastic Solitary Beam Solutions .54 2.7.3 Hybrid Plastic-Me
23、tal Bumper Beam Solutions .58 2.8 Low-Speed Damageability and Lower-Leg Impact-CompliantBumper System .61 2.8.1 Conflicting Energy-Absorbing Requirements for Bumpers 61 2.8.2 Dual-Stage Energy-Absorber Approach.63 2.8.3 Performance Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24、 . 65 2.9 Vehicle Structural Integrity for High-Speed Crashes 66 2.9.1 Hybrid Rail Extensions for Frontal Crashes .67 6351_Book.indb 8 7/9/13 11:17 AMix Table of Contents 2.9.2 Plastic Reinforced Body-in-White Structures 72 2.9.3 A Case Study on Roof Crush Countermeasures 74 2.10 Summary.78 2.11 Tre
25、nds .79 2.12 References 80 Chapter 3 Interiors 87 3.1 Introduction 87 3.2 Instrument Panel 89 3.2.1 Key Drivers in Instrument Panel Design 89 3.2.2 Automotive Instrument Panel Carriers .89 3.2.2.1 Occupant Safety: Head and Knee Impact 89 3.2.2.2 Processing Challenges of Instrument Panel Carriers .91
26、 3.2.2.3 Mold-Filling Simulations of Instrument Panel Carriers .92 3.2.3 Seamless Airbag Design 92 3.2.3.1 Tear Seam Plaque Study.94 3.2.4 Knee Bolster 94 3.2.5 Center Console 95 3.3 Steering Wheel 97 3.3.1 Introduction 97 3.3.2 Metal versus Plastic 98 3.3.3 Design Technology.99 3.3.4 Materials 101
27、3.3.5 Performance Requirements 101 3.3.5.1 Role of Predictive Engineering 102 3.3.6 Prototyping and Testing .103 3.4 Interior Components 105 3.4.1 Roof Energy Absorber.106 3.4.2 Door Handle and Door Pull Cup .110 3.4.3 Speaker Grille Cover 112 3.5 Summary113 3.6 Trends 113 3.7 References .114 Chapte
28、r 4 glazing Applications 117 4.1 Automotive Glazing Overview .117 4.2 Automotive Glazing and Global Regulations .118 6351_Book.indb 9 7/9/13 11:17 AMx Table of Contents 4.3 Automotive GlazingRole of Polycarbonate .118 4.3.1 Weight Reduction.119 4.3.2 Styling and Design Freedom .119 4.4 Characteristi
29、cs of a Glazing System .120 4.5 Structural Performance 123 4.5.1 Design for Structural Stiffness 123 4.5.2 Role of Restraints .123 4.5.3 Role of Curvature.124 4.5.4 Role of Thickness .125 4.5.5 Importance of Adhesive and Its Characterization .126 4.5.6 Adhesive TestingUniaxial Tension 126 4.5.7 Dime
30、nsional StabilityEffect of the Coefficient of Thermal Expansion .128 4.5.8 Simulations and Experiments 129 4.5.9 Design of Experiments Approach .130 4.6 Acoustic Performance .133 4.6.1 Transmission Loss 133 4.6.2 Transmission Loss Spectrum: Glass versus Polycarbonate .135 4.6.3 Sound Transmission Lo
31、ss Performance 135 4.7 Thermal Management.137 4.7.1 Thermal Modeling of Semitransparent Materials: Spectral Transmission and Absorption.138 4.7.2 HVAC LoadAdvantages of Polycarbonate .139 4.7.3 Improved Performance of Electric Vehicles .144 4.7.4 Soak Performance of Polycarbonate Glazing147 4.8 Conv
32、ersion Process .152 4.8.1 Two-Shot Injection Compression Molding .154 4.8.2 First-Shot Injection Compression Molding .154 4.8.3 Sequential Injection Compression Molding.156 4.8.4 Simultaneous Injection Compression Molding 157 4.8.5 Breathing Injection Compression Molding .157 4.8.6 Second-Shot Injec
33、tion Overmolding Process157 4.8.7 Prediction Methodology of Two-Shot Injection Compression Molding Process .158 4.8.8 Part and Tool Development 158 4.8.9 Filling Correlation 160 4.8.10 Warpage Methodology Development161 6351_Book.indb 10 7/9/13 11:17 AMxi Table of Contents 4.8.11 Measurement Setup.1
34、61 4.8.12 Approach163 4.9 Summary165 4.10 Trends 166 4.11 References .166 Chapter 5 Plastic-Metal Hybrid (PMH) Structures 171 5.1 Introduction .171 5.2 Why Hybrid Designs?.172 5.3 Types of Hybrids .173 5.3.1 Overmolding 173 5.3.2 Adhesive Bonding 174 5.3.3 Collar Joining 175 5.3.4 Polymer Injection
35、Forming.175 5.3.5 Direct Metal Deposition .175 5.3.6 Mechanical Fasteners .176 5.3.7 Heat Staking .176 5.4 Reinforcing Structure .176 5.4.1 Closed-Channel Hybrid Structures176 5.4.2 Open-Channel Hybrid Structures .179 5.5 Processing of Hybrids .182 5.5.1 Processing of Closed-Channel Hybrid Structure
36、s182 5.5.2 Processing of Open-Channel Hybrid Structures.184 5.5.3 Mold Design .185 5.6 Performance of Hybrid Structures 186 5.7 Application of Plastic-Metal Hybrids 188 5.7.1 Front-End Module Application Development 189 5.7.2 Design Methodology193 5.7.3 Performance Evaluation . . . . . . . . . . . .
37、 . . . . . . . . . . . . . . . . . 195 5.8 Summary198 5.9 Trends 200 5.10 References .200 Chapter 6 Headlamp Applications 205 6.1 Automotive Lighting Overview 205 6.2 Automotive Lighting Global Regulations 207 6.3 Automotive LightingRole of Thermoplastics .207 6.4 Headlamp Reflectors208 6.4.1 Materi
38、al Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 6351_Book.indb 11 7/9/13 11:17 AMxii Table of Contents 6.4.2 Thermal Management.212 6.4.3 Structural Performance 219 6.4.4 Beam Pattern and Optical Performance 222 6.4.5 Stress-Free Reflector through Reflector Bracket .
39、226 6.4.6 Tooling and Processing 230 6.4.7 Gate Design230 6.4.8 Venting232 6.4.9 Tool Thermal Management 232 6.4.10 Tool Surface Treatment 233 6.4.11 Processing .234 6.5 Headlamp Bezels .234 6.6 Headlamp Lenses.235 6.7 Headlamp AssemblyPedestrian Safety.237 6.8 Summary242 6.9 Trends 242 6.10 Referen
40、ces .243 Chapter 7 body Panels 247 7.1 Introduction .247 7.2 Functional Requirements for Body Panels249 7.2.1 Material Selection in Engineering Thermoplastics Body Panels251 7.3 Fenders .252 7.3.1 Manufacturing Considerations in Fender Design254 7.3.2 Design for Paintability 258 7.3.3 Material Chara
41、cterization and Material Model for Fender Predictive Studies264 7.3.4 Case Study of Finite Element Analysis to Optimize Support Configuration 265 7.3.5 Fender Impact Resistance 267 7.4 Design and Development of the Thermoplastic Tailgates.268 7.4.1 Functional Requirements of Thermoplastic Tailgates
42、269 7.4.2 Tailgate Impact Resistance and Structural Rigidity 271 7.5 Tank Flap271 7.6 Spoiler 272 7.7 Summary273 7.8 Trends 273 7.9 References .274 6351_Book.indb 12 7/9/13 11:17 AMxiii Table of Contents Chapter 8 Under-the-Hood Applications 277 8.1 Introduction .277 8.2 Material Requirements for Un
43、der-the-Hood Applications . . . . . . 278 8.2.1 Heat Aging 278 8.2.2 Chemical Resistance 279 8.2.3 Types of Engineering Plastics in Under-the- Hood Applications280 8.3 Under-the-Hood Application Examples282 8.3.1 Oil Pans .283 8.3.2 Wire Coating.284 8.3.3 Engine Cover 285 8.3.4 Fuel Lines .287 8.4 D
44、esigning of Under-the-Hood Components 287 8.4.1 Turbo Air Duct .288 8.4.1.1 Design Validation .290 8.4.2 Throttle Body 292 8.4.2.1 Types of Throttle Body .292 8.4.2.2 Materials for the Throttle Body293 8.4.2.3 Predictive Tools to Drive Thermoplastics Usage in Electronic Throttle Body .294 8.4.2.4 Pr
45、ocessing of Throttle Body.297 8.4.2.5 Current Status of Thermoplastics in Electronic Throttle Body .299 8.5 Summary300 8.6 Trends 300 8.6.1 Material Advancements .301 8.6.2 Processing Advancements .301 8.6.3 Secondary Process Advancements 302 8.6.4 Design Trends302 8.6.5 Green Trends.303 8.7 Referen
46、ces .303 Chapter 9 Sustainability in the Automotive Industry . 307 9.1 Introduction .307 9.1.1 Sustainability Trends in the Automotive Industry . . . . . . . 308 9.2 Lightweighting and Fuel Efficiency .308 9.2.1 Materials for Lightweighting .309 6351_Book.indb 13 7/9/13 11:17 AMxiv Table of Contents
47、 9.2.2 Quantifying Environmental Benefits of Lightweighting through Life Cycle Assessment . . . . . . . . . . . . . . . . . . . . . . . 311 9.2.3 Life Cycle Assessment Case Studies for Lightweight Materials.311 9.2.4 The Future of Lightweighting with Plastics.314 9.2.5 Design for Sustainability.314
48、9.3 Renewable-Sourced or Bio-Based Materials for the Automotive Industry .315 9.3.1 Why Renewable Resources?315 9.3.2 Carbon Footprint of Bio-Based Raw Materials 316 9.3.3 Bio-Based Materials for Plastics.317 9.3.3.1 Cellulosic Plant Fibers .317 9.3.3.2 Bio-Based Polymers Made from Monomers or Inter
49、mediates from Renewable Resources 319 9.3.3.3 Highly Biodegradable Polymers from Renewable Resources 320 9.3.4 Limitations of Sourcing Raw Materials from Renewable Resources to Make Polymers .322 9.3.5 Emerging Bio-Based Raw Materials .322 9.3.6 Bio-Based Plastics for the Future Automotive Industry . 323 9.4 End-of-Life Scenarios .324 9.4.1 Recycling in the Automotive Industry .324 9.4.2 End-of-Life Options for Selected Polymer Families 326 9.4.3 Challenges and Limitations to Plastics Recycling326 9.4.4 Effect of Recycling on Carbon Footprint Reduction330 9.4.5 Reuse .33
