CASTING WEIGHT REDUCTION BY DIE DESIGN TOPOLOGY OPTIMISATION M.Sc.Aircraft & Mechanical Engineer Kadir Akcan

Transcription

1 CASTING WEIGHT REDUCTION BY DIE DESIGN TOPOLOGY OPTIMISATION M.Sc.Aircraft & Mechanical Engineer Kadir Akcan

2 CONTENTS Company Profile of Ford Otosan A.Ş Project Aim Manufacturing of Sheet Metal Parts and Project Aim Sheet Metal Stamping Cycle Ford Die Design Standards (WDX) Optimisation Phases Manufacturing Phases Test Phases Results

3 LOCATIONS OF FORD OTOSAN A.Ş Industrial Center of Turkey: Marmara Region İnönü Plant Black Sea Sancaktepe Parts Distribution Center Sea of Marmara İstanbul PDC İstanbul Kocaeli Plant Bursa Honda Kocaeli Hyundai Toyota Sakarya Gölcük Plant Renault Tofaş-Fiat Inonu Plant Eskisehir Yeniköy Plant Sancaktepe Engineering Center Automotive industry intensity: Both OEMs, Manufacturers are located in a 110 km radius circle centered on the Kocaeli Factory.

4 FORD TRANSIT, BEST-SELLING VAN IN THE WORLD Longest-running model in Ford of Europe s product range ~ 9 million units produced globally since its launch in 1965 Manufactured by Ford Otosan since 1967 Ford Otosan is the lead manufacturing plant of Transit globally Chassis Cab Van Minibus Loading Capacity: 3.3 tons 4.7 tons Loading Capacity: Seating Capacity: 9.5m m / 17+1

5 FORD CUSTOM Ford Otosan is the single global source of Ford Custom Launched in October 2012 First vehicle in its segment to achieve a maximum five-star Euro NCAP rating Transit Custom (Commercial) Tourneo Custom (People Mover) Loading Capacity: 5.9 m m 3 Long and Short Chassis 8+1 Seating Capacity 4.97m 5.34 m Loading Capacity: 6.8 m m 3

6 FORD COURIER Ford s first vehicle in the compact van segment Ford Otosan is the single global source of Ford Courier Launched in May 2014 Tourneo Courier (People mover) Transit Courier Combi Van (Commercial) Transit Courier Van (Commercial)

7 FORD TRUCKS Manufactured at Ford Otosan s İnönü Plant since 1983 Road truck, construction and tractor series available Cargo 1846T 2013 International Truck of the Year 3 rd place TRACTOR ROAD TRUCK CONSTRUCTION 4x2 Tractor and 6x2 Full Trailer are the main applications. Mainly used for local distribution and municipality (special purpose vehicles) 4x2, 6x2, 8x2 applications. Tippers, Transmixers, Cement Pumps. 6x4, 8x4, 4x2, 6x2 and 8x2 applications. Available in E3&E5 and E6 emission levels with 13L Ecotorq engine generating power 420 and 480 PS Long Haulage Available in E3&E5 and E6 emission levels with 9L and 13L Ecotorq engine generating power 330 and 420 PS Distribution Trucks Available in E3&E5 and E6 emission levels with 9L and 13L Ecotorq engine generating power 330 and 420 PS Construction Trucks

8 ECOTORQ ENGINE FAMILIY Available in 9L 330PS and 13 L 420 to 480PS Environmentally Friendly Euro 6 Emission Levels Turbocharger with Variable-Geometry 2500 bar Common-Rail Fuel Injection System Specially Coated Pistons Smart Charging Alternator

9 PROJECT AIM Minimize: f(x) Subject to : g(x) 0 f(x): Objective function :Minimize Compliance g i (x): Constraints :Volume Fraction (<%30) :Displacement (<1mm) :Stress (220 Mpa) x: FDesign variables :Density of elements? TOPOLOGICAL OPTIMSATION

10 MANUFACTURING OF SHEET METAL PARTS & PROJECT AIM OP20 DRAW OP30 TRIM OP40 TRIM OP50 FLANGE Automative parts manufacture about 3 or 4 die Every die roughly ton Project aims to reduce die weights %20

11 SHEET METAL STAMPING CYCLE Top Press Ram Upper Die Draw Cavity 1.Ready to stamping 2.Cramping Sheet Metal Binder Gas Springs Lower Die Lower Press Ram 3.Forming (Drawing) 4.Openning the press

12 FORD DIE DESIGN STANDARDS (WDX) Helps to design new sheet metal die according to specs Design specs determined with experienced and calculations Some WDX title like below; Die Construction Rib Thickness Rib Distances Air Pins Die Automation Electiral Equipment Die Matarials Screw, Dowels Air Cylinders

13 CONVENTIONAL DIE DESIGN Conventional Die Design Rib Thickness Rib Distances Geometrical Construction OPPORTUNITIY Weight Reduction Pockets Ribs According to WDX Standards. Rough Die Design Die Design According to WDX

14 PILOT PANEL AND FORMABILITY ANALYSIS Sheet Metal Analysis Obtained Contact Pressures New H625 Cargo Back Panel Die Selected as Pilot Part of Project

15 OPTISTRUCT DESIGN SPACE Non design space Design space Non design space Only bottom side of dies selecting as playgraund

16 OPTISTRUCT INPUTS & OUTPUTS Contact pressures transfered to Optistruct with script code Design and non-design spaces defined in Optistruct Objective function and constrains determined in Optistruct Outputs Lower Die Optistruct Result Ribs linked for die design iteration Upper Die Optistruct Result

17 CHECKING THE OPTIMISATION RESULTS BY CAE Static Analysis Dynamic Analysis Results must be OK, if not die design will be revised

18 CHECKING THE OPTIMISATION RESULTS BY CAE Displacements Maximum displacements results obtained

19 ANALYSIS WORK FLOW SUMMARY SHEET METAL SIMILATION DIE DESIGN-1 OPTISTRUCT DIE DESIGN-2 INPUTS Panel data Material Specs OUTPUTS Press force Contact Pressure Feasibility analysis STRAIN GAGES INPUTS Panel data Material Specs Press Specs OUTPUTS Solid die Design No weight reduction INPUTS Solid Design without ribs Contact pressures Volume precentage Max. allowed displacement OUTPUTS Material distribution MANUF. PHASE OK NOK CAE DYNAMIC CHECK NOK OK INPUTS Panel data Material Specs Press Specs Optistruct Results OUTPUTS Die design have ribs Have weight reduction CAE STATIC CHECK OUTPUTS Real strain values CAE TUNE UP OUTPUTS Casted and machined die Try-out INPUTS Design with ribs Press speed Material specs Contact parameters Boundary conditions OUTPUTS INPUTS Design with ribs Contact pressures OUTPUTS Von Mises stress Displacements Contact pressures Von Mises stress Displacements

20 BEYOND STANDARDS WITH OPTIMISATION Conventional Die Design (Cargo H566) Bottom View of Upper Die Optimised Die Design (Cargo H625)

21 OPTIMISED OK TO CAST DESIGN Upper Die View Lower Die View

22 MANUFACTURING PHASES FOAM MODEL CASTING MACHINING ASSEMBLY

23 TEST PHASE Totally 48 strain gages adapted to die surfaces Dynamic strains collected from die with strain gages Dynamic forces collected from press

24 RESULTS Press forces, strain values and CAE outputs will compared next weeks. Technical Results Fiancial Results

25 Questions?