Project description
Improved composite brake disks could find widespread use in cars
The growing need to reduce CO2 emissions is driving automotive manufacturers to increasingly focus on using lighter materials to reduce fuel consumption. Carbon–matrix composites are ideal for use in braking systems as they reduce their weight by 50 % compared to traditional cast iron disks and cut car weight by 25 kg. However, their multi-step batch production process makes them expensive, which greatly limits their market size globally. The EU-funded ROLL-IT project will develop a fully automated process that combines additive manufacturing technology with traditional sheet moulding to enable a continuous forming process for composite brake disks. The new process could help reduce carbon fibre content by 40 %, scrap materials by 70 % and production costs by 50 %.
Objective
Light-weight materials lead to a drastic weight reduction in vehicle components such as the braking system, improving fuel efficiency and vehicle performance. The low density of Carbon Matrix Composites materials makes them ideal for light weight braking systems. CMC brakes are 50% lighter than traditional cast iron discs and their adoption could save up to 25kg/car. They also reduce the braking distance by > 40%. However, they are very expensive. Their production cost (€500) and sales price (€700) is attributed to the multi-step batch production process that includes >7 manual steps done by specialized operators. That is why CMC brake discs accounting for only 1% of the global market. Product quality is also not guaranteed in the current manufacturing process because of inefficient control of the Carbon Fibre (CF) topology which is only achieved by hand or machine positioning. Through this innovation project, we will make CMC brake discs affordable for more customer segments while improving their quality. ROLL-IT is a fully automated process that combines advanced additive manufacturing techniques with traditional sheet molding to enable a continuous forming process of near-to-shape preforms for CMC brake disks, exploiting an affordable processing route on the same machine. ROLL-IT will enable control of the CF topology and that of the material properties that mainly affect the disc performance. CMC manufacturer will benefit from a 600% increase in throughput, 40% decrease in carbo fiber content, 50% reduction in productions costs and a 70% reduction in scrap whilst car owners will benefit from improved mechanical properties of the disc and enhanced safety through a 40% reduction in braking speed. This innovation project will play a significant role in advancing our commercialization strategy. We anticipate a high uptake of ROLL-IT which will boost our sales and elevate PETROCERAMICS from a start-up status to a fully-fledged company.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
- engineering and technologymaterials engineeringfibers
- engineering and technologymaterials engineeringcomposites
- engineering and technologymechanical engineeringvehicle engineeringautomotive engineering
- engineering and technologyenvironmental engineeringenergy and fuels
- engineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturing
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Programme(s)
Funding Scheme
SME-1 - SME instrument phase 1Coordinator
24040 Stezzano
Italy
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.