JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 41

feasible for mass production.
While finalizing this second production
step, Hyundai experts and the partner
companies also combined forces effectively to overcome another challenge when
the adhesion between the composite
insert and the overmoulding resin proved
too weak. They soon adapted the overmoulding resin to deliver the necessary
stability and strength.

Getting the right mixture
While working with different fibres and
composites, a number of variables were
difficult to calculate, e.g. when combining
unidirectional glass and carbon fibre
rovings within the insert. The materials do
not have the same coefficient of thermal
elongation so, when the final insert cools
down, the whole part can twist and deform. Therefore, it was crucial to place the
carbon fibre exactly in the right places and
get the mixture of all materials correct to
avoid any distortion at the end. Hyundai
developed two final versions of the new
insert with different combinations of glass
and carbon fibre rovings to showcase the
potential of the new technology.

Significant weight reduction
The main benefit of the newly developed
process and the resulting front bumper
beam structure, composed of both glass
and carbon fibres, is a 43% (3.6 kg)
weight reduction versus the conventional steel structure. Furthermore, the

additional costs compared to the steel
structure are minimal and, last but not
least, the new structure is fully recyclable:
the thermoplastic materials used for the
composite insert and the overmoulding
can be melted down and reused, which is
not possible with most other solutions on
the market.

Building the first prototype
In order to deliver a prototype, various
meetings of the Hyundai team and
project partners were held and countless
calculations made of how the injection
mould and the pultrusion die should be.
With such new materials and production
processes, there was no experience in
how dimensions might change when the
composite cooled down.
Despite this, the composite insert fitted
straight away when added to the injection
mould, so well that no tooling changes
were made after this prototype stage: a
pleasant surprise, but proof of the huge
effort and professionalism of the Hyundai
team and its highly committed partners. As
a result, the only follow-up work was some
process optimization of the overmoulding
parameters; the dimensions of the pultrusion insert were not modified further.

Mass production feasibility
Part of the mass production challenge was
not just creating the parts and production
process, but the tools to produce the
new structure. So Hyundai and Plastic

About HMETC

Omnium not only created CAD data for
About the Hyundai Motor
Europe Technical Centre
The Hyundai Motor Europe Technical
Centre in Rüsselsheim (Germany) is a
young, dynamic company with its roots
in South Korea. Established in 2003, the
organization has grown constantly since
then; its 250 employees are responsible
for developing and designing future generations of vehicles and technologies for
the whole European market and beyond.

the new front bumper crash beam, but
also simulations for this new structure.
Developing these alone took almost a year
because the final composite material - the
mixture of carbon and glass fibres, and the
resin - simply had not been seen in the
automotive industry before, so no simulation data was available. This meant setting
up extensive mechanical tests under
various conditions to create data, finally
delivering accurate simulation results
ready for mass production application.
But if this aspect had given the development team a temporary headache, it was
more than relieved by realization that the
new materials and processes could cut
short production time.

No compromise on design,
safety and performance

Fig. 5: HMETC award winners President Dr. KIM Moo-Sang, Dr. Richeton, Mr. Ringenbach, Dr. Prescher
(head of Engineering), Dr. Coulton

No98 July - August 2015 /

More information:
www.hmetc.com

Feature Automotive

The resulting front bumper crash beam,
based on the Hyundai i30 front structure,
could now be fitted to the car without any
adaptation to the car structure. Even the
foam elements behind the front bumper
fascia could be re-used with the new parts.
This production compatibility is matched
by the safety of the new part: the front
bumper crash beam fulfils the same specifications as the current steel structure and
passed all relevant crash tests, such as the
low-speed insurance test, the pedestrian
protection test and even the EuroNCAP
50 and 64 km/h crash tests. Furthermore,
the new construction also includes a
towing hook that is fully compliant with
all internal Hyundai load tests as well
(Figure 5). n

jec composites magazine 41


http://www.hmetc.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015

Cover
Edito
Point of view : business development
Contents
COMPANY & BUSINESS
In brief
Cluster
SME
Agenda of Events
APPLICATIONS
Sports & leisure
Safety
Sports & leisure
MARKET
Resins
FEATURE AUTOMOTIVE
Materials
Binder
Additive
CFRP
Epoxy
Hybrid polymer
QSP
CRTP
Rear axles
Tanks
Engines
RESEARCH & DEVELOPMENT
Fractography
Recycling
TECHNOLOGY & INNOVATIONS
Ancillary product
Vision system
Nano
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cover
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Edito
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Point of view : business development
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 5
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Contents
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 7
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In brief
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cluster
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - SME
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 11
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 12
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 13
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 15
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Safety
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad1
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 19
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Resins
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 21
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 22
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Materials
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 24
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Binder
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Additive
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 27
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 28
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 29
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CFRP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 31
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 33
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Hybrid polymer
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 35
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - QSP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 37
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 38
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CRTP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 40
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 41
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Rear axles
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Tanks
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Engines
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 45
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Fractography
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 47
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 48
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 49
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Recycling
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 51
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ancillary product
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 53
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Vision system
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 55
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Nano
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Index
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 59
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 60
https://www.nxtbook.fr/newpress/jeccomposites/jcm2209_147
https://www.nxtbook.fr/newpress/jeccomposites/jcm2206_146
https://www.nxtbook.fr/newpress/jeccomposites/jcm2204_145
https://www.nxtbook.fr/newpress/jeccomposites/jcm2201_144
https://www.nxtbook.fr/newpress/jeccomposites/jcm211_143
https://www.nxtbook.fr/newpress/jeccomposites/jcm2109_142
https://www.nxtbook.fr/newpress/jeccomposites/jcm2107_141
https://www.nxtbook.fr/newpress/jeccomposites/jcm2105_140
https://www.nxtbook.fr/newpress/jeccomposites/jcm2103_139
https://www.nxtbook.fr/newpress/jeccomposites/jcm-experts-digest-additive-manufacturing-2020
https://www.nxtbook.fr/newpress/jeccomposites/jcm2101_138
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_Special_Issue4
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_137
https://www.nxtbook.fr/newpress/jeccomposites/jcm2009_136
https://www.nxtbook.fr/newpress/jeccomposites/jcm2007_135
https://www.nxtbook.fr/newpress/jeccomposites/jcm_2020_Q1_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_Special_Issue3
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_134
https://www.nxtbook.fr/newpress/jeccomposites/jcm2003_133
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
https://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
https://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
https://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
https://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
https://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
https://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
https://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
https://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
https://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
https://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
https://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
https://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
https://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
https://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
https://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
https://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
https://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
https://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
https://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
https://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
https://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
https://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
https://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
https://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
https://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
https://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
https://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
https://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
https://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
https://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
https://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
https://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
https://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
https://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
https://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
https://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
https://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
https://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
https://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
https://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
https://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
https://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
https://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
https://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
https://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
https://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
https://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
https://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
https://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
https://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
https://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
https://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
https://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
https://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
https://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
https://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
https://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
https://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
https://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
https://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
https://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
https://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
https://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
https://www.nxtbookmedia.com