Right Material for the Right Part Identify Cost Effective Routes To Achieving Scalable Solutions For Mass-Market Product - Optimal Multi-Material Combinations Including Aluminium, Magnesium & Composites Dr Mark White Chief Engineer, Body Complete, Jaguar Land Rover Product Development
WEIGHT REDUCTION POTENTIAL 100% 400kg 320kg -10-20% Relative cost Current Steel Optimised Steel 240kg -40% Aluminium 200kg -50% Magnesium 160kg -60% CFRP today 120kg -70%? CFRP? Weight reduction relative to cost
WEIGHT REDUCTION LCA IMPACT 600 500 400 Material Production Energy Use (MJ/kg) 300 200 100 0 Steel Aluminum Magnesium CDRC Production End of Life
200,000+ Sales LWV PRODUCT DEVELOPMENT Timing Plan 2011 2012 2013 O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0-1 -2-3 -4-5 -6 <PA> <FDJ> <VP> <PEC> <FEC><LR> <LS> <J1> <FSR> ent Manufacturing Physical Validation
NEW LWV ALLOY DEVELOPMENT Novelis Anticorodal - 300T61 In comparison to 5754 equivalent parts: 20% weight save achieved 6kg per vehicle 9% cost save per vehicle 12,000 tonnes CO 2 reduced from fleet tailpipe emissions
CRASH VARIABILITY & ROBUSTNESS New crash alloys required for lowest cost & weight of LWV s Developed methods of analysing robustness of structural performance JLR partnership with Suppliers & Fraunhofer Institute
LWV SINGLE PIECE BODYSIDE Two year research project to eliminate separate rear fender panel Developed design & stamping guidelines for high volume LWV s 1.1mm AC170PX aluminium sheet with Depth of draw over 300mm 5 operations per part for benchmark to steel part Saves weight (2.5kg), part & assembly cost & investment
PAINT SHOP SIMULATION Simulation of thermal loading through Paint Thermal induced cosmetic defects highlighted Map of heat transfer throughout the Body Countermeasures designed to avoid defects No additional parts required thinnest gauge
CHOICE OF HPDC & SIMULATION Structural high pressure die castings in Aluminium & Magnesium Rationale Local stiffness in high load input areas Complex geometry & part integration Magnesium high pressure die castings for IP X Car Beam & FEC Challenges: variable cost, supply, quality & wall thickness
THIN WALL DIE CASTING DURABILITY Development of Simulation technique for assessment of high pressure castings in durability load cases
NEW LWV SPORTS CAR PLATFORM F Type Coupe & Convertible can be used to Prove out scalable LWV solutions 11
NEW SPORTS CAR PLATFORM 12
F TYPE BODY STRUCTURE OVERVIEW LWV Body designed as Convertible & Coupe premium sports car 141 Major aluminium pressings 18 High Pressure Die Castings 24 Extruded Profiles (plus hydro-formed side frame on Coupe) 13
EXPLODED VIEW COUPE SIDE FRAME Coupe Side frame designed for US Roof Crush & SUV Side impact 14
CUSTOMER FOCUS LWV TECHNOLOGY Deployable Rear Spoiler Deployable air vents Deployable Door Handles Glass Panoramic roof Aluminium fixed roof CFRP Lightweight roof 15
BONDED ROOF STRATEGY - COUPE Coupe pilot for JLR Bonded roof strategy T&F fit Metal, Glass & CFRP options Improved Design appearance deleting roof ditch finishers Prove out for CFRP as Production part for Lacquered & Painted finish Direct comparison of Quality, Cost, Production & CAE simulation versus Metal Explore Scalability of CFRP for future Body Application at JLR
INNOVATIVE CLOSURES TECHNOLOGY 17
INNOVATIVE CLOSURES TECHNOLOGY Side Doors Warm Formed Door Inner Decklid Composite Construction 18
WARM FORM SIDE DOOR PROJECT 19
WARM FORM DOOR INNER PROJECT Door Inner Panel is JLR s first application of Warm Forming process. Delivering 3kg save, 15% piece cost save & a part count reduction. Dimensional integrity improved reducing error states of multi piece door Warm Forming of Aluminium Sheet is a stamping process developed, in conjunction with Benteler, applied to 5000 series structural alloys. Target steel levels of formability & depth of draw at conventional room temperature aluminium production rates. 165mm Depth of Draw, Design & Legacy Architecture Drives Warm Forming 20!
PREVIOUS DOOR CONSTRUCTION Outer waist Pressing. Inner waist extension. S.I.B. Casting Castersil 37 Heat Treated Outer Panel 6111 Window Regulator Mounting Points Casting Castersil 37 Heat Treated Pressing Covers casting
WARM FORM DOOR CONSTRUCTION Outer Waist Panel. Latch Reinf. Inner Waist Panel. Outer Panel AC600 Inner Panel Warm Formed at Benteler pressed in 5182. S.I.B. Al Extrusion. Hinge Reinf
WARM FORM DOOR INNER PANEL Level of formability not feasible in conventional aluminium stamping processes. Weight saving of 3kg per vehicle to offset increased single part cost. Integration of Multi-piece Architecture, reduces component count & Assembly Cost. 23 Improve dimensional integrity aiding Hardware attachment.
COMPOSITE DECKLID ALTERNATIVE 24
MATERIAL CHOICE CHALLENGES Sweeping Rear Surface Integrated Spoiler Business Equation Weight Decklid Material Customer E-TYPE Light Graphic Short Vertical Flange Assembly Quality BUILDING ON JAGUAR LAND ROVER (JLR) COMPOSITE TAILGATE STRATEGY 25
ERGONOMICS & CUSTOMER USAGE Spoiler location decision critical to material selection Impacted customer access to load space Mass to lift & customer effort experience Significant impact to deck lid structure Designed to meet JLR efforts standard 26
COMPOSITE CONSTRUCTION DRIVERS Deliver A Surface Design with as few parts & as light weight as possible Integration of CHMSL & Spoiler - stamping not feasible in single pressing Design requirement to remove antenna pod on deck lid Need for an antenna transparent part of the deck lid Coupe tailgate also Composite (SMC & CFRP option) 27
COMPOSITE DECKLID COST MODEL 60 50 Breakeven Analysis F-TYPE Deck lid Material Steel - 1 Piece Outer Steel - Multi-Piece Outer Aluminium - 1 Piece Outer Aluminium - Multi-Piece Outer SMC Total Cost Breakeven point SMC V s Metal Multi-Piece 40 Total Cost 30 20 Initial Investment Delivering the A - Surface Design 10 0 Total Cost Breakeven point SMC V s Metal 1-Piece Business Equation Decklid System Integration Volume 25,000 50,000 75,000 100,000 28
JLR LWV SUMARRY The aim of the JLR LWV strategy is to develop product propositions that balances the technical, business & market equations whilst delivering a CO2 offset for the JLR fleet average. Technical Vehicle performance cost & weight Market How many at what price and with what feature? CO2 offset Business Programme & corporate profitability & investment OEM s must address the Sustainability challenge in a cost effective manner, whilst maintaining vehicle attributes & making vehicles that appeal to customers looking at just variable cost of a part will always result in the sub optimal solution
Right Material for the Right Part Jaguar XE The next Aluminium Intensive LWV Thank You, Vielen Dank, Dhany Nad, Grazie, Merci 30