08 - cost modeling of laser-welded blanks in automotive applications

8/3/2019 08 - Cost Modeling of Laser-Welded Blanks in Automotive Applications

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w w w . a u t o s t e e l . o r g

COST MODELING OF LASER-WELDEDBLANK S IN AUTOMOTIVEAPPLICATIONS

J erem y Gregory , Ric h Rot h and Frank Fie ld

Camanoe Associates/MIT

Pet er Mould

Tailored Steel Product Alliance


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I n t roduc t ion

COST MODELING STUDY

Underwritten by Tailored Steel Products Alliance

(TSPA). Camanoe Associates:

Principal developers of the model.

Input from: Jay Baron (Center for Automotive Research)

TSPA Members

Auto/Steel Partnership (A/SP)

American Iron and Steel Institute (AISI)


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Tai lo red St ee l Produc t A l l ianc eTAILORED STEEL PRODUCT ALLIANCE (TSPA)

Alliance of: Tailored steel blank manufacturers

Equipment Suppliers N.A. Steel Companies Organized by AISI Started in January 2006

Cost sharing Purpose:

Promote the use of tailored steel products in automotiveapplications.

Typical Projects: Market applications/trends and growth Understand and share benefits and limitations Develop a COST MODEL for comparing conventional stamping

with laser welded blanks.


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TSPA Mem bersTailored Blank Manufacturers

Noble Metal Processing, Inc.Nova-HyfoPowerlasers

ProCoil Company, LLCShiloh Industries, Inc.Tailor Steel AmericaTWB Company, LLC

Equipment Suppliers

N.A. Steel Companies

Soutec SoudronicVIL/Wayne Trail Technologies

AK Steel CorporationDofasco, Inc.Mittal Steel U.S.A.Nucor CorporationSeverstal North America, Inc.

United States Steel Corporation



Genesis o f Cost Model ing Pro jec tCOST MODELING

Targeted as the No. 1 project for TSPA in 2006 Drivers and needs:

Identify and compare ALL costs in stamping of conventional,

monolithic parts and laser-welded blanks. Basis for a COST-BENEFIT analyses in specific applications. User-friendly. Flexible to allow input variations.

Independent analysis, proven and accepted methodology.

CAMANOE ASSOCIATES/MITExperience in cost modeling for:- Ultra Light Steel Auto Body (ULSAB)- Light Weight Front End Structure (LWFES)

A/SP study



St udy Objec t ives

Analyze three case studies (TSP & baseline):

compare fabrication costs & cost drivers

Rail

Body side inner

Door inner (not presented here)

Model capable of two cost methodologies Direct Cost Estimation

Variable Burden Rate (not presented here)



Out l ine

Cost modeling methodology

Rail Case Study

Body Side Inner Case Study

Observations



Di rec t Cos t Es t im at ion Methodo logy :Proc ess-Based Cost Model i ng Cost model uses manufacturing requirements costs

Processing requirements Cycle times, equipment specifications

Resource requirements Number of tools, equipment, and laborers

How do technology changes impact manufacturing cost?

Process

Model

Operations

Model

Financial

Model

Production

Cost

Processin

g

Requirements

Operating Conditions Factor Prices

Resource

Requirements

Product

Description



TSPA Cost Analys is Met hodology -DCE Blanking, Stamping, Rollforming, & Assembly

PBCM Methodology

Welding Cost input ($/weld length), includes:

Welding, inventory, defects, admin, shipping, materialpremium, other

Cost Breakdown Variable: Material, Labor,

Other (Process Material, Energy) Fixed: Equipment, Tooling,

Other (Building, Maintenance, Overhead)

Welding


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Out l ine


Rail Case Study


Observations


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Rai l Basel i ne Design

Rail OuterRail Inner Rail Control 1

Control Reinf 1

Trans-Ext

Control Reinf 3

Under Body Rail

Trans-Reinf

Rail Reinf 2

Rail Reinf 3

Rail Reinf 4

Control Reinf 2

Rail Control 2

13 Pieces


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Rai l LWB Design

Rail Extension Reinforcement

Rail Extension

Inner Rail Reinforcement

Outer Front Rail

Bumper Beam

Rail Extension Reinforcement

Inner Rail Reinforcement

Outer Front Rail

Inner Front RailBumper Beam

5 Pieces


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Rai l Design Cont ent

Baseline LWB

# ofParts Weight(kg) # ofParts Weight(kg)

Stampings 24 26.8

5.432.2

# of Spot Welds 562 320

4 4.5

Tailored Blanks 2 6 18.9TOTAL 26 10 23.4

Includes left & right assemblies

LWB Design has more HS Steels


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$0

$50

$100

$150

$200

$250

Base 50k LWB 50k Base 275k LWB 275k

TotalUnitCo

st(L&RAsse

mblies)

Assembly

LWB Stamp^

Ord. Stamp*Material

*Ord. Stamp =Ordinary Stamping

(including blanking)

^LWB Stamp =LWB Stamping(including blanking& welding)

50k = 50,000/yr

275k = 275,000/yr

Base = Baseline

LWB = LWB

$203

$155

$127

$105

Uni t Cos t Break dow n: Proc esses


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$0

$50

$100

$150

$200

$250


Total

UnitCost

(L&RAssemblies) Welding

Other*

Tooling

EquipmentLabor

Material

*Other includesprocess materials,energy, building,maintenance, andoverhead

$203

$155

$127

$105

Uni t Cos t Break dow n: Fac t ors


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Uni t Cost Produc t ion Vo lum e Sens i t i v i t y

$0

$50

$100

$150

$200

$250

0 50 100 150 200 250 300

Annual Production Volume (x 1,000)

Tot

alUnitCost(L&R

Assemblies)

Base

LWB


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Conc lus ions f rom Rai l Case St udy LWB design is less expensive than baseline

Use of HS Steels and LWBs improves LWB design

Less material and weight Fewer parts

More expensive HS Steels negate cost savings from

weight reduction in LWB design but parts consolidation significantly decreases LWB

assembly costs


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Out l ine


Rail Case Study


Observations


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Body Side Inner Base l ine Design

5 Parts: FBHP, Rocker, Center Pillar,Wheelhouse, Roof Rail


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Body Side Inner LWB Design

6 Welded Blanks: FBHP, Rocker, Center Pillar,

Wheelhouse, Front Roof Rail, Rear Roof Rail


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Body Side Inner Design Cont ent

Baseline LWB

Rollformings 2 9.5 -- --

# of

Parts

Weight

(kg)

# of

Parts

Weight

(kg)Stampings 8 50.6

--

60.1

# of Spot Welds 116 --

-- --

Tailored Blanks -- 2 43.8

TOTAL 10 2 43.8

Includes left & right assemblies

Same materials in both designs


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$0

$50

$100

$150

$200

Base 50k LWB 50k Base

275k

LWB

275k

T

otalUnitCo

st(L&RAss

emblies)

Assembly

Rollforming

LWB Stamp^

Ord. Stamp*Material

$171

$129 $120

$95

*Ord. Stamp =Ordinary Stamping

(including blanking)

^LWB Stamp =LWB Stamping(including blanking& welding)

50k = 50,000/yr

275k = 275,000/yr

Base = Baseline

LWB = LWB

Uni t Cos t Break dow n: Proc esses


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$0

$50

$100

$150

$200


Total

UnitCost

(L&RA

ssemblies) Welding

Other*

Tooling

Equipment

Labor

Material

$171

$129$120

$95

*Other includesprocess materials,energy, building,maintenance, andoverhead

Uni t Cos t Break dow n: Fac t ors

Uni t Cost Produc t ion Vo lum e Sens i t i v i t y


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$0

$50

$100

$150

$200

$250

0 50 100 150 200 250 300

Annual Production Volume (x 1,000)

Tot

alUnitCost(L&R

Assemblies)

Base

LWB

Conc lus ions f rom


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Body Side I nner Case St udy LWB design is less expensive than baseline

Cost drivers

Material: LWB is 33% lighter; less material costs Tooling: 1 tool for LWB design (per side) vs. 4 tools

for baseline (per side)

Forming time: 1 part for LWB design (per side) vs. 5parts for baseline (per side)

Assembly: None required for LWB design

Out l ine


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Rail Case Study


Observations

Observat ions


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LWB Designs are less expensive than baseline

counterparts for assemblies studied here

Door case study has similar results Keys to cost-effective LWB designs

Reduce mass (less material cost) Reduce parts (less forming time, tooling, and

assembly)

To a certain extent, this can come at the expense of

more costly materials (e.g., HS Steels) and

production processes (e.g., blank welding)

Cont ac t In form at ion


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Jeremy Gregory, Camanoe Associates

[email protected]

Peter Mould, TSPA

[email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Bac k up Sl ides

Weld ing Cost Break dow n


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Source: Tailor Welded Blanks: General Design Guidelines to Minimize Cost, 2000,

Auto/Steel Partnership Tailor Welded Blank Project Team.

Note that blanking costs excluded from welding costs

in this analysis they were calculated separately.

08 - cost modeling of laser-welded blanks in automotive applications

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