Engineering - Clemson Composites https://clemsoncomposites.com A new center at Clemson University Fri, 03 Apr 2020 16:57:12 +0000 en-US hourly 1 https://wordpress.org/?v=6.7.1 Hybrid single-shot process for metals and composites streamlines and increases cost savings in manufacturing https://clemsoncomposites.com/hybrid-single-shot-process-for-metals-and-composites-streamlines-and-increases-cost-savings-in-manufacturing/?utm_source=rss&utm_medium=rss&utm_campaign=hybrid-single-shot-process-for-metals-and-composites-streamlines-and-increases-cost-savings-in-manufacturing Tue, 31 Mar 2020 15:52:18 +0000 https://clemsoncomposites.com/?p=249361

hybrid single-shot process for metals and composites streamlines and increases cost savings in manufacturing

MOTIVATED BY THE CONCEPT of the integrative production systems, hybrid process of polymer injection molding and sheet metal forming, known as Hybrid Single-Shot (HSS), has been introduced to manufacture sheet metal-polymer components using a single tooling, machinery, and operating system. During this process, the sheet metal blank inside the injection mold is deformed by means of tool movement and/or by pressure of the polymer melt. As the melt cools, the injected polymer is permanently bonded to the deformed sheet metal depending upon the existence/use of any bonding agents.

DIGITAL TWIN

Invented by Clemson researchers Srikanth Pilla and Saeed Farahani, the novel process can help reduce the time and cost it takes to manufacture components that are composed of different materials and need to be joined together. The process is aimed at streamlining the manufacturing of some components, such as the center consoles in high-end cars.

GOALS AND METHODOLOGY

One of the goals is to reduce the cost of making vehicles lighter, which improves their mileage and helps automotive companies meet federal fuel efficiency standards. But researchers said the technology could be used in a variety of industries, including home appliance manufacturing.

The new method could reduce infrastructure costs and cycle time, while helping ensure that the pieces are mistake free and fit snugly together. The technology could be ready for the manufacturing floor in as little as two years.

When some parts are made conventionally, one machine stamps sheet metal into the desired shape, and another machine creates polymer or composite parts. Then the pieces are bonded together with glue.

In hybrid single-shot manufacturing, it’s all done in one machine. The technology can be used in existing equipment, obviating the need for major capital investment, Pilla said.

As part of the research, Farahani built a “concept design tool,” and covered it with sensors that measure everything from temperature to pressure. He also created his own software that allows researchers to create a computer model of the machine’s process, also called a “digital twin.” The digital twin coupled with artificial intelligence is playing a crucial role in teaching the machine to operate on its own.

Researchers also plan to test the new technology at the Clemson Composites Center with the goal of making real components.

hybrid single shot sheet metal

Publication Links

The post Hybrid single-shot process for metals and composites streamlines and increases cost savings in manufacturing first appeared on Clemson Composites.

]]> Design and analysis of roller bearing cages https://clemsoncomposites.com/design-and-analysis-of-roller-bearing-cages/?utm_source=rss&utm_medium=rss&utm_campaign=design-and-analysis-of-roller-bearing-cages Fri, 27 Mar 2020 16:48:54 +0000 https://clemsoncomposites.com/?p=249217

Design and analysis of roller bearing cages

IN COLLABORATION WITH JTEKT KOYO, Clemson researchers advanced the fundamental understanding of material and process dynamics for optimal design of a bearing’s polymeric cage.

PROCESS DYNAMICS

JTEKT North America is a leader in automotive bearings. It has been a part of the Clemson University International Center for Automotive Research since 2006.

roller illustration

OBJECTIVES AND PARTNERSHIPS

MAIN TASKS

  1. MATERIAL SELECTION and process physics optimization
    • Design of the cage geometry
    • Material selection
    • Design of the mold
    • Fabrication of the mold
    • Injection molding of cage
    • Injection molding of tensile specimens
    • Characterization and testing
  2. EFFECT OF FLUID such as moisture and oil on the properties and geometrical dimensions of polymeric cages
  3. FORCE COMPUTATION for assembly/disassembly of rollers in cage by modeling the geometry of the cage and the deformation mechanism. The required force to push out the roller from the cage was calculated according to the stiffness of the cage material.

PARTNERS

  • Koyo
  • JTEKT Corporation
roller cage

PARTNERS

  • Koyo
  • JTEKT Corporation

The post Design and analysis of roller bearing cages first appeared on Clemson Composites.

]]> Ultra-lightweight 100% recyclable scalable production door https://clemsoncomposites.com/ultra-lightweight-100-recyclable-scalable-production-door/?utm_source=rss&utm_medium=rss&utm_campaign=ultra-lightweight-100-recyclable-scalable-production-door Wed, 25 Mar 2020 14:12:55 +0000 https://clemsoncomposites.com/?p=249314

ULTRA-Lightweight 100% recyclable scalable production door

IN 2016, CLEMSON UNIVERSITY RESEARCHERS began work for a $5.8 million grant from the U.S. Department of Energy to pioneer technology for fuel-savings, energy efficiency, and to meet the U.S. corporate average fuel economy standards.

RECYCLABILITY

Working with industry partners, the Clemson team engineered and constructed an ultra-lightweight thermoplastics composites door that enables innovation for greenhouse gas reduction, recyclability, and circular economy.

John W. Gillespie, director of the University of Delaware Center for Composite Materials (CCM), and assistant director Shridhar Yarlagadda issued a joint statement:

“Clemson and CCM are establishing a strong partnership to merge auto systems design with composites materials, design and manufacturing to lightweight composites door for high-volume production.”

PARTNERSHIPS AND ACHIEVEMENTS

GOALS

  1. Achieve a 42.5% weight reduction
    • Base weight = 31.8 kg | Target Weight = 18.28 kg
  2. Zero compromise on performance targets
    • Similar crash performance
    • Similar durability and everyday use/misuse performance
  3. Maximum cost induced is 5$ per pound. (.453 kg)
    • Allowable cost increase = $ 150.1 per door
  4. Scalability
    • Annual production of 20,000 vehicles
  5. Recyclability
    • Project goal is 100% recyclable (self imposed)

PARTNERS

  • Honda R&D Americas
  • U.S. Department of Energy
lightweighting door illustration

The post Ultra-lightweight 100% recyclable scalable production door first appeared on Clemson Composites.

]]>