A structured approach to the design and manufacture of SMC components
The CPC GROUP (Modena, IT) leads a scientific program in collaboration with LMAT Limited (Bristol, UK), and the University of Bologna, with the aiming to provide a better understanding of Sheet Molding Compound (SMC) material behaviour during processing and crash events.
The CPC GROUP (Modena, IT) leads a scientific program in collaboration with LMAT Limited (Bristol, UK), and the University of Bologna, with the aiming to provide a better understanding of Sheet Molding Compound (SMC) material behaviour during processing and crash events. This program is being funded by the Regional Development Fund of Emilia Romagna region and has been built to investigate the ways in which SMC can be processed and designed making it a cost-effective lightweight alternative to metallic solutions in the highly competitive automotive market.
SMC is a composite material that is widely used in the automotive industry due to its high strength-to-weight ratio, fatigue performance as well as its resistance to corrosion. SMC parts are typically greater than 25%lighter than steel parts (>50% in some crash applications), making them a logical choice for components such as hoods, trunks, fenders, and doors. In addition to their strength, durability SMCs offer the ability to be molded into complex shapes. The composition of the material can be altered to meet specific requirements, such as increased stiffness, improved impact resistance, or enhanced fire resistance. This makes SMC materials a versatile option for a wide range of automotive applications.
"The process starts with SMC charge placement optimization in order to achieve a uniform distribution of fibres throughout the part and complete mold filling. This improves the material's mechanical properties and reduces variability in the final product."
The process starts with SMC charge placement optimization in order to achieve a uniform distribution of fibres throughout the part and complete mold filling. This improves the material's mechanical properties and reduces variability in the final product. The charge placement optimization involves determining the optimal location and orientation of the raw material relative to the mold cavity. This is done using computer simulations and modelling techniques provided by LMAT.
Once the mold filling simulation is complete the material fibre vectors including local variations in the volume fraction are mapped onto a structural model which is subsequently used to simulate component behaviour in crash events. The unique simulation approach pioneered in this program takes into account the 3D orthotropic nature of the composite material including localised effects of ribs and inserts. The use of novel 3D damage predictive techniques will allow CPC to make increasingly complex, cost effective structures with a significant reduction in the component and process design time as well as elimination of trial and error approaches to tooling evolution.
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