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Semblex Henkel

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hydro

ADAPTIVE DFS PARTNER

Deptra

AUTOMOTIVE STEEL PARTNERS

US Steel

CO-SPONSORS

TOX

2019 Summit Agenda

Day One: Tuesday, February 19, 2019

Advances In Mixed-Material Joining And Forming Strategies, Technologies And Manufacturing Processes For High Strength Steels, Aluminum Alloys, Advanced Plastics And Composites

08:00  Coffee and Registration

09:00  Chair's Welcome And Introduction

COST-EFFECTIVE STRATEGIES FOR JOINING OF HIGH STRENGTH STEELS AND ALUMINUM ALLOYS

OPENING PANEL - SENIOR VP'S OF BODY STRUCTURE ENGINEERING

09:10  Cost Effectively Implementing Transformative Technology For Mixed Material Joining - What Are The Latest Technologies & Innovations?

  • Comparing different methods of joining aluminum to steel in terms of costs and payback  
  • Best practices specifically on joining of new high strength steels and aluminum alloys
  • How to manage the joining process with different coatings and interfacial treatments
  • Achieving a balance between lightweighting, vehicle performance and corrosion performance for EVs
CASE STUDY: GEN 3 JOINING AND MANUFACTURING

09:40  Joining And Manufacturing New High Strength Steels And Aluminum         Alloys - Applying Innovation To Technology, Treatments And Coatings

  • Applying innovation and quality enhancements to the joining process
  • Examining the latest transformative technology for joining HSS and aluminum
  • New steel alloys for the lightweighting of vehicle components and assemblies
  • Developments in high strength Gen 3 steels with good formability at the 1000Mpa and 1200Mpa levels
  • Managing springback for improved dimensional control 
  • Dealing with Liquid Metal Embrittlement (LME) and porosity challenges in welding processes
CASE STUDY: METALS TO CARBON FIBER

10:10 Innovations In New Fastener Types And Rivets For Joining

  • Aluminum, Carbon Fiber And Steel
  • Developments in new lightweight fastener types and riveting for mixed material structures and reduced vehicle weight
  • Joining aluminum and carbon fiber to each other and to steel
  • Implications for mechanical fastening approaches with the adoption of Industry 4.0, increased automation and automated assembly cells    

10:35  Questions and Discussion       

10:45  Networking Coffee Break In Exhibition Area

OPTIMIZING STRUCTURAL ADHESIVE USE AND APPLICATIONS

PRESENTATIONS & PANEL DISCUSSION - ENHANCING ADHESIVE PROCESSES

11:15  Adhesive Application Optimization And Manufacturing Process                    Verification

  • How much to put down for a given structure and avoid problems with over application?
  • What are the full characteristics under welding?
  • Developments in adhesive materials that enable greater control during application and processing and are more stable over long periods of time
  • Avoidance of weld and paint application quality issues through improved wash resistance

11:50  Role Of Chemistry In Lightweighting The Battery Electric Vehicle

  • Potential for smart chemistries to enable OEMs to meet lightweighing goals
  • Paving the way for new vehicle structures
  • Using different resins and fibers
  • Structural hybrid solutions for EV battery protection

Brooke Virost, Business Development Manager, Henkel Corp.

Eugene Chung, Business Development Manager,Henkel Corp.

ROBOTIC TECHNOLOGY & ADHESIVE BONDING APPLICATIONS

12:25 Inline Robust 3D Inspection And Process Control Of Bead Dispensing

  • Importance of inline inspection of bead quality with structural adhesives and sealants
  • Utilizing 3D machine vision to inspect complex parts during the manufacturing assembly process to ensure highest quality finished components
  • High speed inline inspection to increase throughput

Zhenhua Huang, General Manager of Americas,Coherix

12:50 Questions and Discussion

13:00  Networking Lunch In Exhibition Area

NON-DESTRUCTUVE TESTING AND QUALITY CONTROL MONITORING IN JOINING PROCESSES

ULTRASONIC TESTING 

14:00  Non-Destructive Testing (NDT) Process Development For Cost-                   Effective Joint Quality Monitoring

  • Developments in ultrasonic evaluation approaches for different joint types
  • What can be done to make the technology more robust for widespread use in the body shop?
  • Inspection of laser joints for pores
  • Non-destructive evaluation (NDE) of adhesive processes without dissembling
AUTOMATED VISION SYSTEMS AND DIMENSIONAL CONTROL

14:45  Developments In Automation For Inspection And AssuringQuality And      Dimensional Control In The Body Shop

  • Role for automation in ensuring enhanced dimensional control in manufacturing and reducing time to achieve objectives in new production lines
  •  Automated vision systems for optimized joining, assembly and dimensional control
  • Inspecting Class A surfaces visible to the customer with laser scanning at high resolution and high volume rate to provide surface quality validation

15:20  Questions and Discussion

15:30  Networking Coffee Break In Exhibition Area

FASTER, MORE COST-EFFECTIVE MANUFACTURING PROCESSES FOR ADVANCED PLASTICS AND COMPOSITES JOINING COMPOSITES TO METALS

16:00  Innovations In Joining Plastics And Thermoplastics To Steel Sheet Metals And Sheet Aluminum Alloys

  • State-of-the-art in mixed-material joining solutions enabling lightweight, more efficient vehicle designs and structures for e-mobility 
  • Reducing the number of different joining technologies in multi-material body structures
  • Strength and durability considerations in hybrid joint types including adhesive-mechanical and adhesive welding

16:30  Questions and Discussion   

16:40  Advances In Manufacturing Tools Using New Energies For Manufacturing Processes Manufacturing Processes

  • Advancements in material systems and processing
  • Innovation in laser cutting of hydro-formed components
  • Induction heating tools for cutting of materials and pre-curing adhesive bonded joints and sealants closure components
  • Evaluation of energy utilization with various joining processes
HP-RTM AND NCF

17:10  Advanced Plastics And Carbon Fiber Composite Processes For Lightweighting

  • Achieving faster cycle times and lower cost production with composite components through high pressure resin transfer molding (HP-RTM)
  • Low cost non-crimp fabric (NCF) processes for high delamination resistance and impact strength - benefits in achieving complex shapes
  • Benefits in terms of faster and cheaper production processes than unilayer based processes
  • What is the progress towards $5 per lb for carbon fiber reinforced material?
  • 3D printer pre-forming opportunities
  • Potential for replacing carbon fiber with bamboo strands - strength, weight and cost
  • Developments in highly scalable sandwich hybrid composite technologies for greater lightweighting than carbon fiber alternatives for EV and autonomous vehicle applications

17:40  Questions and Discussion

17:50  Chair's Closing Remarks - Day 1

18:00-19:00 Networking Drinks Reception For All Attendees

 

Day 2: Wednesday, February 20, 2019

Enabing Greater Integration, Reduced Process Complexity, More Flexible A Increased Production Capacity With Industry 4.0, Simulation And Manufacturing Technology Advancements

08:00  Coffee And Registration

09:00  Chair's Opening Remarks

ADOPTING SIMULATION AND MODELING TOOLS FOR EFFECTIVE JOINING, WELDNG, FORMING AND ADHESIVE BONDING

PRESENTATIONS & PANEL - MANUFACTURING PROCESS MODELLING

09:10  Advances In Simulation And Modeling Of Manufacturing Processes To Reduce Production Costs And Minimize Physical Testing

  • Innovations in predictive modeling of welding, stamping and adhesive joining processes to reduce physical testing processes
  • Modeling of material properties for crashworthiness testing   
  • Simulating the assembly line for to ensure throughput and clearances 
  • Benefits in bringing new manufacturing plants and production online quicker

09:45  Composite Materials Simulation And Modeling For Enhanced Lightweight Body Structures

  • Opportunities to reduce complexities in design so that you can look at manufacturing effects on performance
  • Designing to use carbon fiber where exactly needed so you can change the density to match loadings on the component and optimize composite manufacturing processes

10:15  Questions and Discussion   

REDUCING COMPLEXITY IN EV ASSEMBLY

10:25  Design For Manufacturing - Advanced Casting And Extrusion Processes Adoption For Increased Integration

  • Reducing complexity in sub-assemblies and parts count in electric vehicle assembly
  • Adoption of new extrusion alloys and processes
  • Applications of extrusions for energy absorption including crash rails, bumpers and door intrusion beams

10:50  Questions and Discussion   

11:00  Networking Coffee Break In Exhibition Area

UNDERSTANDING AND REALIZING THE POTENTIAL FOR DIGITALIZATION AND INDUSTRY 4.0 MANUFACTURING

DIGITALIZATION AND INDUSTRY 4.0

11:30 Exploiting Digitalization Of Automotive Manufacturing Under Industry 4.0 For Smarter Faster Production And Improved Profit Margins

  • Potential for new software and collaborative IT to enhance product design and  transform traditional production and supply chain inefficiencies
  • Achieving more agile manufacturing through leveraging artificial intelligence (AI), advanced analytics, sensors, machine learning and IoT
  • Benefits in terms of faster tooling turnaround and lower capital investment with EVs and autonomous vehicles

12:10  Adopting Digital Twin For Integrated Design And Manufacturing To           Reduce Process Time And Cost 

  • Enabling a digital footprint of a product from design to development and throughout the entire product life cycle
  • Modelling and simulating real time manufacturing processes
  • Managing the performance, effectiveness, and quality of fixed assets such as machines, lines, and plants using advanced visualization, IoT, and analytical tools
  • Case studies on digital twin in automotive design and production

12:45  Questions and Discussion   

13:00  Networking Lunch In Exhibition Area

ADOPTING AUTOMATED CELLS AND FLEXIBLE ASSEMBLY LINES FOR INCREASED PRODUCTION EFFICIENCY

FLEXIBLE CELLS AND ASSEMBLY

14:00  Maximizing Agility In Manufacturing For The Electric And Autonomous Customized Vehicle Future

  • Adopting automated assembly to reduce processing complexity and increase production capacity
  • Saving time and cost through adoption of flexible cells and flexible assembly lines - including robotic assembly cells
  • Stability in assembly cells and assembly lines
  • Universal intelligent robotic programming and simulation software for multi cell and robot configurations
  • Optimization and predictive maintenance in manufacturing  

14:35  Questions and Discussion   

INCREMENTAL FORMING

14:45  Maximizing Lightweighting In Steel Automotive Bodies And Frames With    The Steel Tube Air Forming (STAF) Process

  • Hotel metal air forming
  • Flange forming technology
  • Optimization of hot forming process

Ryuichi Funada, Technical Marketing, STAF Project, Sumitomo Heavy Industries

ADDITIVE AT LARGE SCALE

15:20  Progress Update On Manufacturing Process Enhancement Through Additive At Large Scale With Metals

  • Scaling up additive and 3D manufacturing for metals
  • Current capabilities - Where can additive manufacturing support high volume applications now? - In future?
  • Where is the break over volume in industrial additive manufacturing? - How fast can you do it and at what volume are you better off just making the tool?
  • Case studies on potentially transformational applications

15:50  Questions and Discussion

16:00  Networking Coffee Break In Exhibition Area   

MATERIALS CUSTOMIZATION AND DEVELOPMENTS IN ADVANCED MANUFACTURING PROCESSES

ICME AND MATERIAL COCKTAILS

16:30  Advances In Materials For Lightweighting That Will Make A Difference And Enable Advances In Manufacturing

  • The situational vision for the future - Opportunities for parts consolidation and functional integration with tailored materials to reduce manufacturing costsRole for Integrated Computational Materials Engineering (ICME)
  • Designing and exploiting customized material cocktails for structural applications
  • Material systems that have potential for automation and faster processes
MANUFACTURING PROCESS INNOVATION

17:00  Key Applications And Processes For MetamorphicManufacturing And Robotic Blacksmithing

  • Looking ahead - The potential for more agile manufacturing and lower cost processing
  • Optimizing the metamorphic manufacturing process with deformation and heating to improve material properties 
  • Delivering benefits in cost and time savings in vehicle production

17:30  Questions and Discussion   

17:40  Chair's Closing Remarks - Amazon Echo and Champagne Draw

17:50  End Of Conference

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