In September, 2011, at the International Auto Show (IAA) held in Frankfurt, smart and BASF jointly exhibited the world's first new model: Smart's new concept car "smart f road simulation input orvision", which is the world's first car with thermoplastic wheels. However, this model is not only the development alliance of civil aircraft materials industry, but also the performance test of this model has been carried out for mass production by COMAC relying on the concept car of SAIC
smart all plastic wheels are 30% lighter than standard aluminum wheels. The plastic wheel weighs only 6kg and is manufactured by the new special polyamide Ultramid structure of BASF company. With this wheel, the weight of the vehicle is greatly reduced by 2kg. The complete set of wheels consists of two parts: the actual support assembly and the wheel housing (which is also manufactured by BASF Ultramid). Both components have support functions and can carry high loads under driving conditions. The wheel housings can be painted in a variety of vehicle coloursHeiko Hess, who is responsible for the wheel development of BASF company, explained: "thermosetting plastic wheels have been used in racing cars and have been produced in small batches. However, compared with the plastic wheels of thermoplastic 2 and fatigue testing machines that can be injection molded, their manufacturing process is complex and the cost is high, so they are not suitable for mass production."
special plastic for high load occasions
ultramid structure is BASF's first long fiber reinforced (LF) polyamide product, which was first introduced at k 2010 plastic exhibition. At the beginning of research and development, this kind of material aims to replace metals and achieves significant improvement in performance. When highly optimized short fiber reinforced products encounter bottlenecks, long fiber polyamide provides new opportunities
smart forvision all electric concept car has been tested for mass production.
parts made of long fiber reinforced plastic can form a three-dimensional glass fiber structure through conventional injection molding process, so that the finished products have excellent physical properties at high and low temperatures. Thanks to this structure, the warpage, creep and energy absorption behavior of long fiber reinforced plastics are close to that of metals, while maintaining the traditional advantages of plastics
computer aided design
like many Ultramid components in recent years, this high-strength Ultramid wheel is designed using the universal simulation tool UltraSim of BASF company. For this new polyamide, BASF has also made corresponding improvements to UltraSim, so that it can simulate the behavior of long glass fiber reinforced parts. The final experimental results are consistent with the simulation results. According to BASF, the component design assistance service that has reached such a perfect level is still blank in the field of long fiber polyamide
the shape and position of the stiffener on the plastic wheel are predicted and optimized directly on the computer by using the UltraSim software and the topology optimization method, without compromising the design. At the early stage of design, the wheel shape manufacturer has determined the professional analytical tape peel strength tester, which only needs to make minor changes to the actual production parts. Therefore, in close cooperation with the wheel experts of Daimler company, this component highly related to safety was developed in a very short time. Previously, it was only made of metal. At smart and BASF, a large number of load tests were carried out on the wheels
evaluation of test results
plastic wheels have passed a variety of steel/aluminum alloy wheel standard tests, such as fatigue test, wheel biaxial test, impact test and radial runout test, to determine their mass production potential. During the test, the wheels have withstood the test of high-speed driving in curves, emergency braking, driving in pits, bumping along the road and other harsh conditions. (end)