automotive lightweight materials manufacturing congress · § biw weight reduction methods, ......

AutomotIve LIghtweIght MaterIals ManufacturIng Congress BODY & paınt LIGTHWEIGTH DESING CHALLENGES 29-30 November 2016 / Bırmıngham, UK

Engin YILMAZER November 29-30, 2016

agenda

§ Who we are? § Our Products § BCE Tool Manufacturing timing § Weight Overview on Transit Custom § Material Overview on Transit Custom § BIW weight reduction methods, challanges and solutions on transit custom

§ Stamping of Aliminium panels § Aliminium assembly Joining process § Paint challanges of Aliminium / Steel assemblies

Company Confidential


Gölcük Plant Transit(2001) /Custom(2012)

Sancaktepe Parts Distribution Center –1998 Sancaktepe R&D Center - 2015

İnönü Plant - 1982

Locations of Plants & Facilities

4

Yeniköy Plant – Courrier (2014)


Who are we? Kocaeli bce vome team

Our Projects

New Transit

Tourneo Courier

Tourneo Custom


Lead manufacturing plant of the new generation Transit

ASSEMBLY SHOP

BODY SHOP

TOOL&DIE PRES SHOP

Gölcük Plant

PAINT SHOP

Opened in 2001

1,600,000 m2 total area; 340,000 m2 covered area

Transit 140k Custom 150k


Yeniköy Plant The single production center of Ford Courier in the world

New production facility at Gölcük plant site opened on 22 May 2014

70,000 m2 covered area

Environment and disabled-friendly plant

Courier 110k


Annual Production Capacity 415,000

Gölcük 290,000

Yeniköy 110,000

İnönü 15,000

Total Employees 10,676

Blue Collar 7,944

White Collar 2,732

KEY PERFORMANCE METRICS

Transit

Custom

Courier

Cargo

Chart Title

Blue Collar

White Collar


We are an effective team that manufactures high quality Body Construction Line and Products on low budgets.

Who are we? Kocaeli bce vome team


VEHICLE PROJECT TIMING: 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 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

J1 FSR

Targets Defined

“Will Use”

“Should Use”

1

2

3

4

5

6

1

3

1

55 1

Select Specific SystemCase 1 (Sporty Wagon)

Case 2 (Luxury Wagon)

V0 V1 V2 M-1DwgUnderbody

V0 V1 V2 VP Dwg

P.RE

Upperbody

Verification Testing

ReDV

TTBuild

PPBuild MP

Verification Testing

Launch

MP1 build

MP2 -Acceleration

M1 VP1st

Homol.

Design Alternatives Theme Design Production Design / Surface Dev.

St Releases (S,A,B,C)

Design Verif.Single Theme<FC0> <FC1> <FC2> <FC3>

<FC4>

<FC5>

Design

FeasibilityStampingProcess Planning

ToolDesi

P/C/R/P

Pattern / Casting / Raw Material / Pre Mach

FMFinal Machining

Production Release Complete

Un X1

“Could Use” Inputs from

Pre-PS

20-90veh.

50-150 veh.

OKTBLSLR

FECPECVPMR PS

FDJ

PAPTCPSC

Up X1

T-Release

LAUNCH

PRE-PS ACTIVITYPRODUCT PLANNIG

<AA1>

<FAA>

SFB0 PCF

TCB

Quality Fixtures

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 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

BCE TOOL MANUFACTURING TIMING:


WEIGTH OVERVIEW IN TRANSIT CUSTOM: Body structure

Low Strength Steels

Advanced High Strength Steels Press Hardened Steels

High Strength Steels

Total weight body-in-white without doors, closures and fenders: 492.1 kg


WEIGTH OVERVIEW IN TRANSIT CUSTOM:

Front bumper beam: 10.6 kg

Closures/ doors/ hood: 127.1 kg

Body-in-white weights of doors, closures and fenders

Front doors (both): 47.6 kg Sliding door (single) 31.9 kg Hood: 10.6 kg Tailgate: 26.0 kg Front fenders (both): 5.3 kg

Hang-on parts


2. Material mix in the body-in-white including doors and closures Based on metallurgical/chemical material classes

Materials: corresponding metallurgical classes RGB colour code %

Stee

ls

Low Strength Steels: Mild steels R 153, G 204, B 255 59.23 High Strength Steels (HSS): High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA)

R 051, G 102, B 255 26.84

Advanced High Strength Steels (AHSS): Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP)

R 255, G 153, B 204 5.74

Stainless steels: Austenitic stainless steels R 051, G 051, B 153 - Ultra High Strength Steels (UHSS): Complex Phase Steels (CP), Martensitic Steels (MS)

R 204, G 153, B 255 -

Press Hardened Steels (PHS) R 128, G 000, B 128 8.19

Alu

min

ium

Aluminium sheets: 7xxx series R 051, G 204, B 153



Aluminium extrusion profiles R 153, G 204, B 000

Cast aluminium R 051, G 153, B 102

Magnesium R 255, G 255, B 000

Plas

tics

Fibre reinforced plastics R 255, G 000, B 000

Duroplastics, including Sheet Molding Compound (SMC) R 255, G 153, B 000

Thermoplastics R 153, G 051, B 000 Other materials, namely:_________________________________________________

R 192, G 192, B 192

Materıal OVERVIEW IN TRANSIT CUSTOM:

The following graph may serve as a guide to locate the properties of the metallurgical steel classes:

0

400

800

1.200

1.600

2.000

0 200 400 600 800 1.000 1.200 1.400

Tens

ile S

tren

gth

/MPa

Yield Strength /MPa

HSLA

BH

Low Strength Steel

High Strength Steel

Ultra HighStrength Steel

Advanced HighStrength Steel

CP

MS

PHS

Press Hardened Steel

Mild

TRIP

DP

HSIF

Ref only


LIGHT WEIGHT materıal OVERVIEW IN FORD


Tem

pera

ture

Resistance Spot Welding

Hybrid Joining

Arc and Laser Brazing

Plasma Welding Arc Stud Welding

Inert Gas Arc Welding MIG, MAG, TIG

Laser Welding

Bonding

Self-Pierce Riveting Clinching

Bolt joining Flow Drilling

Screws Hemming

Car Body - Joining Technologies

Source : SCA Presentation


•  Frt. Member Floor Side for Ford Custom : –  Boron Side Members –  Tailor welded blank –  With three different thickness –  and one different material grade.

FRT.STRUCTURE WEIGHT REDUCTION

Previous Transit Design (Multi Piece Design )

Successor Transit Custom Design


Typical V363 VBK Rr Underbody

ReAR UNDERBODY LADDER WEIGHT REDUCTION

•  Complexity Management

•  Complexity Management •  Part deletion for specific

derivative. •  Gauge difference •  Grade difference

•  Complexity Management •  Gauge difference

•  Complexity Management •  Gauge difference •  Grade difference

•  Complexity Management •  Gauge difference •  Grade difference


BODY CONSTRUCTION LINE SOLUTION: •  Rear UN Floor Side BCE Process Flow Changes & Challenges

–  Conventional air pressured guns and AC transformers are not capable to supply repeatable weld quality . DC MF guns and controls required.

–  Tailor welded blank drives muti-joint conditions which does not suit manual spot welding process and dictates robotic application.

–  Automation lines requires more space but there is no new building assumption for the change over

–  Weld parameter setup requires more prototypes to verify due to time constraints –  Weld quality checks needs different calibration on US controls.

–  Assembly tooling locator concept is affected needs new tooling and change over period is critical .

–  Above Process dictates high initial investment which is not competitive in Turkey OEMS.


ReAR UNDERBODY LADDER automatıon

•  Additional Robots •  Extra Space requirement + existing line

relocations •  Part Loading solutions which changes

MP&L assumptions as well •  High Investment comparing to manual

solutions. •  Project management difficulties due to

running line


A New Model For Automation Projects

1 Specification & Contract Turnkey Project ( %100 ) +

Specification & Contract

Design & Layout

+ Outsource ( %85) + 2


Design & Layout

+ PLC & Robot Programming

+ 3 Outsource ( %50 ) +


Design & Layout

+ + 4 Outsource (%15)


Design & Layout

+ + 5 Electric Mechanic +

Automation Project process Layout Design Materials Tooling Electric Mechanic Robot PLC

PLC & Robot Programming

PLC & Robot Programming

Materials

Materials

+

+

+

+


Next steps for weıgth reductıon -Alumınum closures

Hang-on parts

Closures / doors / hood :


•  Tolerances: Skin panels: max 0,5 mm Inner Panels: max 1 mm

Panel

Lower die

Part Sprung back

Previos aplication New Application

•  Trim die is deforming panel because of the spring back

•  1st trim die has been machined according to *stl data taken from simulation files.

STAMPING TOOLS FOR ALUMINIUM


1.  Blank seperation on Destacker : •  Running both ALU/Steel blanks in the same destacker cause

bottleneck. •  We have to install additional blowers and increased the pressure

to 12 bars to loading the blanks properly.

Aluminium blanks

Major Issues Whıle StampIng of alu. panels


2. Oil spec. for Aluminium Blanks: We also change the spec to get 0,3 - 0,5 gr/m2 oil on the blanks. Lessons learnt form Valencia Stamping Plant (Alu/ Steel Press Line) 3. Cleaning the Presses: Whole presses are cleaned manually. Approximately 10 - 15 min. It is done in parallel with the die change. 4.  Rework Area: The rework area should be different than steel one.

Major Issues WhIle StampIng of alu. panels


5. Scrap Shedding System: We haven’t enough area to install additional conveyor system for Alu/Steel panel scraps. We have plan to solve this issue with 2 option.

Trucks

Pipe Line

Sharing Series

Press Shedder

Conveyor Output

1. Vacum System (high volume) 2. Elevator System (low volume)

System Cost =5,6 M € System Cost = 850 K €

Major Issues Whıle StampIng of alu. panels


Aluminum Welding properties

Major Issues Whıle alu assembly Joınıng process


Rivet



What is Rivet ?



Rivet Quality Indicators



Rivet Quality control System



Robotic Cell- Rivetting Gun


Engin YILMAZER November 29-30, 2016 29/11/2016 Confidential

Phosphate Coating Process

§  Phosphate coating ,which is the first step of paintshop processes , is currently applied by zinc phosphate. If this material contact with aluminum,it will produce 5 times more mud than current level.

Ø  Galvanic produces 1,5-2 gr/m3 of mud, while Aluminium produces 10-12 gr/m3 of

mud. §  The mud ,Na3AlF6 (krolit), that is formed by contact of the Phosphate bath and

aluminium surfaces, has a hard structure due to iron-fluorine combination in it and may cause clogging of the mud.

Possible Risks •  Poor quality and rework of the vehicle due to high mud formation. •  Clogging of the installation due to increase of phosphate mud formation and rust

formation due to loss of circulation. •  Loss of bath temperature due to sludge accumulation between heat exchanger

plates and loss of production.


Solution Ø  Prevention of mud formation by switching to COLD PHOSPHATE Technology

Supplier Product FordApprovalStatus FordUsers ExceptFordUsers

PPG Zircobond FordGlobal&FoE Illinois,USACuau8tlan,Mexico

GeneralMotors

PSA

Iveco

Daimler

Freightliner

Chemetall Oxilan NA NA

PSA

Opel

Daimler

Renault

TATAMotors

Hyundai

TeslaMotors

Henkel Tectalis FordGlobal&FoE

Michigan,USAMissouri,USAKentucky,USA

Cologne,Germany(2017)Valencia,Spain(2018)

GeneralMotors

QorosAutomo8ve

PSA


•  Switching to Hyper Throw E-Coat Technology Plan: for old cabins (December 2016)

•  Renewal of washing spray nozzles : (August 2016)

•  Additional Circulation pumps

•  Filtration system regulations and additives

•  Transformation of the 1st bath to deluge bath

•  Additional installations between bathes

Requirements of Cold Phosphate

Cologne Plant Trial


Metal substrate

Paint coating

Metal substrate

Zinc-Phosphate

Process Comparison - Layout Coat Thickness

Coating thickness 40 - 100 nm

Paint coating

Cold Phosphate


Operating Parameter

Cleaning Zinc

Phosphate Rinsing Passivating Rinsing Activating

ZnPh DI Rinsing

Cleaning Rinsing DI Rinsing New Technology

DI Rinsing

New Technology

DI Rinsing


How does this Alternative work?


Ford Lane Keeping Alert Ford SYNC Emergency Assistance

§ Euro - NCAP "Advanced Rewards"

§ Five Stars Euro – NCAP §  first vehicle in its segment to achieve maximum rating

Safety ımprovements

J. Büchner / E. Yilmazer of 37 October 22 – 24, 2013

THANK YOU FOR YOUR ATTENTıON!

Q & A ?

automotive lightweight materials manufacturing congress · § biw weight reduction methods, ......

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