Descripción del proyecto
Tecnología de fabricación híbrida para estructuras tolerantes a los choques
Gestionar eventos inesperados es difícil, especialmente en el complejo entorno de fabricación actual. Pero es posible. El proyecto FLEXCRASH, financiado con fondos europeos, desarrollará una tecnología de fabricación híbrida aplicando patrones superficiales mediante fabricación por adición a piezas formadas previamente. La fabricación híbrida ofrece una capacidad de ajuste de las propiedades que permite desarrollar un nuevo tipo de estructuras tolerantes a los choques con un rendimiento sobresaliente en caso de impacto inminente. El proyecto definirá estas estructuras según los parámetros de colisión identificados en distintos escenarios de tráfico mixto y, con ellas, las soluciones ideales para dispositivos de seguridad activa. La tecnología se puede aplicar a otras estructuras relacionadas con la seguridad en piezas de vehículos, donde permite reducir el número de materiales y procesos necesarios para fabricar estructuras de choque y los costes de fabricación.
Objetivo
Flexcrash aims to develop a flexible and hybrid manufacturing technology based on applying surface patterns by additive manufacturing onto preformed parts. Aluminium alloys have been selected as the optimum material to build high performance structures, addressing both lightweight and environmental sustainability. They provide better recyclability, affordability (low CRM content), and costs than other material alternatives that would need complex developments for joining, recycling, and manufacturing. The property tailoring capacity offered by hybrid manufacturing will permit to develop a new type of crash-tolerant structures with outstanding performance under a wide range of impact angles and unexpected crash conditions. Structures will be defined according to the collision parameters identified by the different mixed traffic scenarios. Such tailored structures are the ideal solutions for dynamic active safety devices that allows displacement of crash structures to optimally face an imminent crash. Considering that the frontal crash is the most common (70%), a front-end structure has been chosen as demonstrator to validate the manufacturing developments, the modelling approach and the testing methodologies. The flexibility of the proposed technology will facilitate its transferability to other safety-related structures in vehicle’s locations with higher risk for passenger’s injuries while decreasing the number of materials and processes used to manufacture a crash structure. Simplify supply chain will turn into 20% manufacturing costs saving and reduce the risk of disruption.
Virtual testing with improved reliability, validated by crash tests, will be used to propose new testing configurations, looking at the next step towards standardization. The application of Flexcrash solutions to the whole BiW offers a lightweighting potential up to 20% with improved safety (toward 50% reduction of passenger’s injuries and fatalities).
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HORIZON-RIA - HORIZON Research and Innovation ActionsCoordinador
08290 Cerdanyola Del Valles (Barcelona)
España