ISMR June 2022 - Page 52

HYBRID TECHNOLOGIES

HOLLOW-

With its simulation tools , LANXESS can predict the maximum stresses that hollow-profile hybrids , such as automotive cross car beams ( left-hand screen ), can withstand and at what point they will fail . Photo : LANXESS .

PROFILE HYBRIDS

“ Hollow-profile hybrid technology is a further development of the ‘ traditional ’ plastic-metal composite technology ( hybrid technology ) using sheet metal .”

LANXESS is launching its hollow-profile hybrid technology on the market . With this new lightweight design technology , metallic hollow profiles can be functionalised on conventional injection moulding machines with plastic compounds . The results are plasticmetal composite components that boast “ far greater torsional stiffness and strength than could previously be achieved with other technologies for functionalising hollow profiles ,” LANXESS told ISMR .

“ Hollow-profile hybrid technology has now progressed to such an advanced level that we have embarked on a variety of development projects with customers and have already reached the prototype stage with some of them ,” said Dr . Matthias Theunissen , a specialist in lightweight design at LANXESS .

Hollow-profile hybrid technology from LANXESS offers plastic-metal composite components with greater torsional stiffness and strength .

Potential applications in the automotive industry include cross car beams , coupling rods , stabilisers and seat elements . In addition , the new lightweight technology could be used to produce skiing and hiking poles and components for furniture and the construction industry , for example .
Short cycle times
Hollow-profile hybrid technology is a further development of the “ traditional ” plastic-metal composite technology ( hybrid technology ) using sheet metal . The general strength of the new technology is that processors can manufacture with short cycle times , as is typical for injection moulding in high-volume production .
“ As a result , the manufacturing process is efficient and economical . There is no need for auxiliary units or tooling technology , which keeps investment costs low . The fact that reasonably priced hollow profiles with relatively large dimensional variations can be used , helps to make the process cost-effective , too ,” explained LANXESS .
As Theunissen explained : “ With the help of innovative tolerance management , we can prevent profiles of that type from damaging the mould or stop leaks occurring in the injection moulding cavity .”
When the thin-walled hollow profiles are over-moulded with the molten plastic , high pressures often exceeding 400 to 500 bar occur in the cavity . As a result , there is a high risk of the profiles deforming or collapsing .
“ We have optimised the process so that the profiles can withstand the pressures that occur and do not need to be supported from inside ,” said Theunissen .
30 % weight saving
Demonstrator components produced at LANXESS using the hollow-profile hybrid technology . They are characterised by a high degree of torsional stiffness and strength . Photo : LANXESS .
For its hollow-profile hybrid technology , LANXESS offers highly reinforced polyamide 6 types such as Durethan BKV60H2.0EF DUS060 , which has a short glass fibre content of 60 per cent by weight . With their high strength and stiffness , these compounds can further enhance performance of the corresponding components .
In a simulation study , LANXESS examined how using the compounds pays off in the design of an automotive cross car beam .
52 | sheetmetalplus . com | ISMR June 2022