2014 GREAT DESIGNS IN STEEL CONFERENCE Wednesday, May 14 th 2014

Size: px

Start display at page:

Download "2014 GREAT DESIGNS IN STEEL CONFERENCE Wednesday, May 14 th 2014"

Opal Webb
6 years ago
Views:

1 2014 GREAT DESIGNS IN STEEL CONFERENCE Wednesday, May 14 th 2014

2 2015 Ford Mustang This image cannot currently be display ed. Shawn Morgans Technical Leader & Front End / Under Body Applications Manager - NA Ford Motor Company

3 Agenda Background Material Usage Design Approach Functional Performance Static Static Stiffness Dynamic Dynamic Stiffness Safety Safety

4 BACK GROUND

5 Heritage 5

6 Global Footprint Engineering: Manufacturing: Dearborn 2 Model Coupe and Convertible

7 MATERIAL USAGE

8 BIW Materials Martinsitic & Boron Mild DP1000 DP800 Bake Hard DP HSLA 8

9 Closures Materials Aluminum Boron Mild HSLA Bake Hard 9

10 DESIGN APPROACH

11 Front Structure Conventional Straight Rail Design Torque Box Transfers Load to the Rocker 2 Primary Load Paths: 1. Rocker 2. Sled Runner HSLA mm 11

12 Rear Rail 2014 Mustang 2015 Mustang Redesign of the Rear Rail required to accommodate the transition for a Live Axle to an Independent Rear Suspension Reduced number of stampings in the Rear Rail from 14 to 9 Introduced DP800 in place of HSLA 350 for the main rail stamping and major reinforcement 12

Platform Convertible Adds Performance Pack Tower to Tower Brace add as standard equipment

structure added as a bolt on structure post body shop 35% Increase in torsional stiffness

mode Additional components required to achieve attribute targets for the convertible

13 Platform Convertible Adds Performance Pack Tower to Tower Brace add as standard equipment for convertible 10% Increase in torsional stiffness V-Brace and added attachment structure added as a bolt on structure post body shop 35% Increase in torsional stiffness 38% Increase in the rear end torsional stiffness 16% Increase in frequency of torsion mode Additional components required to achieve attribute targets for the convertible structure. To minimize the impact to the body shop platform adds were designed as bolt in applications 13

14 Design Challenges Roof lowered to balance proportions with new windshield angle Hidden B-Pillar provides modern side view appearance A-Pillar angle decreased to achieve desired windshield rake Revisions to the geometry of the green house increased the difficulty in meeting the new safety requirements Multiple concepts investigated to for the A-Pillar, Roof Rail, and B-Pillar to contain the intent of the design while meeting the revised performance requirements 14

15 A-Pillar / Roof Rail Design Initial studies yielded: 25% Reduction in Variable Cost 9% Reduction in Mass 30mm reduction in functional section height Mild Gage: 1.2mm HSLA 350 Gage: 1.6mm DP1000 Gage: 1.5mm DP1000 Gage: 2.0mm HSLA 350 Gage: 1.8mm HSLA 350 Gage: 1.8mm DP1000 Hydro-formed Tube Gage: 2.0mm 2014 Mustang 2015 Mustang 15

reduction in driver s vision Enabled the

16 Vision Section 2014 Mustang 2015 Mustang Hydro-Form Benefits: Improved structural performance without a reduction in driver s vision Enabled the introduction of an air curtain within the existing package envelop

17 Convertible A-Pillar HSLA mm HSLA mm DP1000 Hydro-Form 2.0 mm Introduction of the use of a hydro-formed tube for the A-Pillar of a convertible is a Ford 1 st DP mm 17

18 B-Pillar Laser Weld Hinge Pillar Reinf 1.5mm HSLA 350 Upper 0.9mm Mild Lower Boron 2.0mm DP mm Boron Laser Welded Blank 1.6mm Upper 1.2mm Lower Upper B-Pillar section reduced significantly with the hidden pillar required for styling. Load requirements for this area increased 2014 Mustang 2015 Mustang 18

the Hydro-Form A-Pillar / Roof Rail to augment welding

19 Joining - Adhesive 27 meters of adhesive in the BIW primarily in the platform Added between Body Side Outer and the Hydro-Form A-Pillar / Roof Rail to augment welding Addition in the Body Side Trough and Under Body to improve BIW stiffness 19

welding used due to improved cycle time, elimination of expendables, and reduced heat input 25 mm laser stitches used to achieve

20 Joining Laser Welding 25 mm Laser Stitch Weld Laser C Weld Assembly of the Body Side Ring conducted at a supplier facility Laser welding used to join the stamped components to the Hydro-Formed tube to optimized the performance of the system Remote laser welding used due to improved cycle time, elimination of expendables, and reduced heat input 25 mm laser stitches used to achieve equivalent performance of a conventional RSW with minimized overlap C-Shaped welds used where welds experienced multiple load directions 20

21 Joining - Laser Welding Ford 1 st Remote Laser Weld Cell installed in the assembly plant to support the Body Side build A combination of stitch and C-Shaped welds used to join the Body Side Outer to the Body Side Ring 21

22 FUNCTIONAL PERFORMANCE

Mass Efficiency Overall increase in vehicle size to improve proportions and competitiveness within segment Increases in safety requirements and improved performance.

23 Mass Efficiency Overall increase in vehicle size to improve proportions and competitiveness within segment Increases in safety requirements and improved performance. Maintained BIW mass status from carry over vehicle L-Factor L-Factor (M BIW / (K T * A S )) M BIW : BIW Mass K T : Torsional Stiffness A S : Shadow Area 1 0 Predecessor Competitor 2015 Mustang Competitive 2014 Mustang 2015 Mustang 23

Coupe Static Stiffness 18000 Bending Stiffness

24 Coupe Static Stiffness Bending Stiffness (N/mm) 21 % Improvement Predecessor 2015 Mustang Torsional Stiffness (kn ( m/rad) 31 % Improvement Predecessor 2015 Mustang 24

25 Convertible Static Stiffness 6000 Bending Stiffness (N/mm) Predecessor 2015 Mustang Torsional Stiffness (kn ( m/rad) % Improvement Predecessor 2015 Mustang 25

Coupe BIP Dynamic Stiffness 46 45 44 43 42 41 40 39 44 43 Vertical Bending (Hz) ( 9%

26 Coupe BIP Dynamic Stiffness Vertical Bending (Hz) ( 9% Improvement Predecessor 2015 Mustang Torsion (Hz) 1.6% Improvement Predecessor 2015 Mustang 26

Coupe BIP Dynamic Stiffness Bending Stiffness (N/mm) 20 15 10 5 0 25 Predecessor 2015

27 Coupe BIP Dynamic Stiffness Bending Stiffness (N/mm) Predecessor 2015 Mustang Torsional Stiffness (kn ( m/rad) 3.8 % Improvement Predecessor 2015 Mustang 27

28 Load Path Front Structure Sub-Frame provides a lower load path into the structure Hydroformed A-Pillar provides load path to the upper structure Press Hardened back up structure supports the Rails and distributes load Press Hardened Rocker Reinforcement provides strength to manage high axial loads Front Rail load distributed to the sled runner, hinge pillar, and rocker. 28

29 Frontal Impact 29

30 Frontal Offset 30

31 Load Path :Roof : Strength & Side Impact Hydroformed A-Pillar distributes load to Headers, Hinge Pillar, and B-pillar Press Hardened floor cross-member and AHSS Headers provide paths for cross vehicle load sharing Press Hardened B-Pillar provides resistance to buckling due to lateral and axial loads Press Hardened Rocker Reinforcement provides transverse load distribution 31

32 Side Impact 32

33 Roof Strength 33

34 Thank You for Your Attention 34

LIGHT WEIGHT BODY IN WHITE DESIGN

LIGHT WEIGHT BODY IN WHITE DESIGN Jason Balzer Lightweight Body & Joining Technical Leader Ford Motor Company September 26 th, 2017 Agenda: Why Light Weight BIW Light Weight Design Mindset 2 Miles per