session 2 - speaker 3 · session 2 - speaker 3.pptx author: sue peterson created date: 6/14/2017...

6/13/17

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3rd Genera)on Ford F-‐150 die-‐cast Magnesium Radiator Support Evolu)on Lightweigh.ng with Magnesium Die-‐cas.ngs

Ford F-‐150 Full-‐Size Truck

Magnesium Radiator Support Introduc.on

Cas.ng Design, Innova.ons & Performance

Galvanic Corrosion and Coa.ng

Manufacturing Process and Tool Design

Conclusions

PRESENTATION OUTLINE

LIGHTWEIGHTING WITH MAGNESIUM DIE-‐CASTINGS

IMPROVED FUEL EFFICIENCY

§  A mass reduc.on of 100kg improves fuel efficiency by 2.2%*

§  Extend the range of electric vehicles

SECONDARY BENEFITS

§  Improved accelera.on, braking and handling

§  Improved towing capability

§  Compounded downsizing of components

Magnesium die-‐cas.ngs are beneficial in the automo.ve industry for vehicle mass reduc.on

Increased use of Magnesium die-‐cas)ngs in body structure applica)ons, such as radiator supports, can help achieve CAFÉ requirements.

* Ricardo Inc., Impact of Vehicle Weight Reduc.on on Fuel Economy for Various Vehicle Architectures, 2008.

LIGHTWEIGHTING WITH MAGNESIUM DIE-‐CASTINGS

CHALLENGES

§  Designing an open sec.on for part ejec.on necessitates crea.vity to meet s.ffness requirements

§  Redesigning magnesium die-‐cas.ngs to further reduce component mass while mee.ng performance requirements

ADVANTAGES

§  Fluidity of molten magnesium to design a large part

§  Can be designed with local ribbing, gussets and thicknesses as required

§  Can be used to adach mul.ple func.onal components (brackets, sensors, etc.)

U.lizing magnesium die-‐cas.ngs for radiator supports has both challenges and advantages

FORD F-‐SERIES FULL-‐SIZE TRUCK Best selling vehicle in the US since 1981

§ Marketed and manufactured by Ford since 1948

spanning 13 genera.ons.

§  Beginning in 2004, F-‐150 has u.lized a Magnesium

Radiator Support.

§  Over 5,000,000 vehicles spanning 3 genera.ons.

§  Targeted aggressive mass reduc.on in current

genera.on design with Aluminum body structure.

1993 F-‐150

2004 F-‐150

2009 F-‐150

2017 F-‐150

THE 2017 FORD F-‐150 FULL-‐SIZE TRUCK Magnesium Die-‐Cast Radiator Support

§  The magnesium die-‐cas.ng is the main structural

component of the radiator assembly.

§  The magnesium die-‐cas.ng is the thinnest and lightest

radiator support ever produced by Meridian.

§  Nearly 10% mass reduc.on from previous genera.on

magnesium cas.ng.

§ Magnesium die-‐cast radiator support was primarily

designed by Meridian, and is manufactured by Meridian

in Eaton Rapids, MI.

*Ref: Ford Media.com

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MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION Three Genera.ons -‐ Introduc.on

2004 MY 2009 MY 2015-‐2017 MY

Geometry (L X H X D) 1670mm x 540mm x 310mm 1500mm x 450mm x 240mm 1590mm x 460mm x 340mm

Mass Reduc.on 35% from previous gen. 60% from 2004 MY 10% from 2009 MY

MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION Three Genera.ons -‐ Styling

*Ref: Ford Media.com *Ref: Autobytel *Ref: Kelly Blue Book

MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION 2004 MY – Significant Innova.ons

Cas)ng part of an assembly:

§  Steel lower bridging & shotgun brackets §  Aluminum spacers

§  Nylon body mount bushings

Cas)ng and assembly:

§  First magnesium radiator support in industry

§  Coa.ng process developed for magnesium cas.ng applica.on

§  Replaces mul.-‐piece steel weldment design resul.ng in a 16 part reduc.on*

§  Direct mass reduc.on of over 4kg and addi.onal compounding mass reduc.on of another 4kg*

*Ref: Balzer et al., 2003-01-0186 SAE Paper



Redesigned front-‐end:

§  Elimina.on of bridging brackets and spacers

§  Elimina.on of lower rail in magnesium cas.ng design

§  Cas.ng design driven by front end design Cas)ng design:

§  Results in nearly 60% mass reduc.on from 2004 design

§  Redesign to meet structural and assembly requirements



Implementa)on of New Technologies (i.e. Aluminum):

§  Increase of 100mm or over 40% in depth of cas.ng

§  Cas.ng design supports addi.onal components

Cas)ng design:

§  Results in nearly 10% mass reduc.on and 17% nominal wallstock from 2009 design

§  Nearly 75% mass reduc.on from pre-‐2004 steel design

§  Design changes to meet addi.onal structural requirements and modified assembly constraints


MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION Three Genera.ons -‐ Assembly

2004 MY 2009 MY 2017 MY

Substrate Steel shotgun / wheelhouse Steel hydroformed rails Aluminum hydroformed rails

Method Steel bridging brackets welded Fastened to rails Fastened to rails

Considera.ons Front-‐end s.ffness Galvanic corrosion

E-‐coat bath contamina.on

Galvanic corrosion Durability performance

Adachment loca.ons Durability performance

Moun.ng addi.onal components

*Ref: Ford Media, KCAP Assembly

*Ref: Getty *Ref: Fourwheeler.com

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MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION 2004 MY – Structural Performance

Sta)c s)ffness was a design driver.

§ Magnesium cas.ng was primary cross-‐car front-‐end structural component

§ Magnesium cas.ng design resulted in equivalent to or greater s.ffness than steel stamping assembly

Substan)al CAE and component and vehicle valida)on performed.

§ Magnesium cas.ng passed 150% of designed fa.gue life without issue*

§  Displacement / .me input measurements developed to ensure crash requirements met.

§  Considerable component-‐level tes.ng performed to ensure material performance *Ref: Balzer et al., 2003-01-0186 SAE Paper



Durability targets drove design.

§  Steel hydroformed rails designed to direct impact forces up and over cabin

§  Lower steel rail incorporated into structure

§ Magnesium cas.ng designed to endure fa.gue life adached to hydroformed rails

Sta)c s)ffness and strength.

§  Designed to meet s.ffness between hydroformed upper rails

§  Designed for hood-‐latch reten.on target

*Ref: SVT Perf.

*Ref: Fourwheeler.com


Topology Op)miza)on.

§ Magnesium cas.ng design op.mized to improve structure and reduce mass

§  Significant s.ffness and strength increases from 2009 MY

§  Cas.ng designed for tougher addi.onal load cases §  Hood bumper load, transport sag, increased lower radiator mount loading

New Aluminum hydroformed rail design.

§  Cas.ng moun.ng loca.ons wider and deeper requiring improved design for s.ffness

Ac)ve grille shu`ers and redesigned headlamps.

§  Cas.ng supports these new components and others totaling nearly 16X its own mass

*Ref: KC Star

*Ref: Cleveland.com

MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION Three Genera.ons – Design for Galvanic Corrosion

2004 MY 2009 MY 2017 MY

Ma.ng Material Steel body Steel rails / steel fasteners Aluminum rails / Steel fasteners

Method Welding using steel brackets Fastened to rails Fastened to rails

Mi.ga.on 1. Aluminum spacers; 2. Nylon bushings;

3. Thread forming screws.

1. Aluminum top-‐hat washers; 2. Cap.ve Aluminum washers 1. Cap.ve Aluminum washers

*Ref: Getty *Ref: Cleveland.com *Ref: Getty *Ref: Getty *Ref: Getty

MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION Coa.ng Process for Appearance

All three genera)ons are coated with epoxy powdercoat in-‐house at Meridian.

§  Coa.ng process developed for 2004 MY radiator support to act as a layer of corrosion protec.on for the cas.ng.

§  In 2017, coa.ng primary func.on is to provide black cosme.c appearance only.

MAGNESIUM RADIATOR SUPPORT DESIGN EVOLUTION 2004 MY -‐ Manufacturing Process & Tool Design

Single cavity tool development.

§  Geometry of cas.ng and required ga.ng area drove a single-‐cavity tool design.

§  Cas.ng necessitates a large tonnage DCM based on projected area, die-‐draw, etc.

§  From review of several die lay-‐out concepts, it was decided to gate the cas.ng inverted.

§  Ga.ng system op.mized using CAE simula.on tools.

2004 MY Die Layout

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Double-‐cavity tooling.

§  Change in ga.ng strategy due to elimina.on of lower rail.

§  Die-‐layout studies iden.fied poten.al for dual-‐cavity capability in a larger-‐tonnage DCM.

§  Calcula.ons performed to determine sufficient ga.ng area available to gate between two cas.ngs.

§  CAE tools were used to simulate the filling and solidifica.on processes to op.mize the ga.ng system and overflow and ven.ng design.

2009 MY Die Layout


Thinnest radiator support within Meridian.

§  Advancements in tooling and manufacturing enabled a 17% reduc.on in nominal wallstock.

§  Ex. Smoothened surfaces and transi.ons, larger radii.

§  Despite increases in cas.ng geometry, general dual cavity tool design and ga.ng strategy carried over.

§  Extensive CAE simula.ons completed to validate a ga.ng system, ven.ng and overflow design and process op.miza.on for ultra-‐thin wallstock.

2015 MY Die Layout

CONCLUSIONS xxxx

§  This presenta.on describes the development of three genera.ons of die-‐cast magnesium radiator supports in Ford F-‐150 trucks.

§  Successive designs have u.lized significant performance and manufacturing advancements to adain weight reduc.on and improved

performance.

§  This presenta.on describes developments in: cas.ng design, assembly & corrosion mi.ga.on strategies, and manufacturing

processes.

§  In summary, three genera.ons of die-‐cast magnesium radiator support design have resulted in:

§  The first applica.on of its kind in the industry,

§  Genera.on-‐over-‐genera.on weight savings provided to the vehicle.

Let it be Light

session 2 - speaker 3 · session 2 - speaker 3.pptx author: sue peterson created date: 6/14/2017...

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