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![Page 1: LIGHT WEIGHT BODY IN WHITE DESIGN - GACC · PDF fileLIGHT WEIGHT BODY IN WHITE DESIGN Jason Balzer Lightweight Body & Joining Technical Leader Ford Motor Company September 26th, 2017](https://reader035.vdocuments.us/reader035/viewer/2022081605/5a82d6407f8b9a24668e045a/html5/thumbnails/1.jpg)
LIGHT WEIGHT BODY IN WHITE DESIGN
Jason BalzerLightweight Body & Joining Technical LeaderFord Motor Company
September 26th, 2017
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2
Agenda:
• Why Light Weight BIW
• Light Weight Design Mindset
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Fuel Efficiency Targets
3
Source: Green Technology, 2011.
Light-Duty Vehicle Fuel Economy Standards, 1978 - 2025
Mile
s p
er G
allo
n E
qu
ival
ent
Model year
54.4mpge
Fleetwide average in 2025
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Impact of Vehicle Mass on Fuel Economy
Gas Guzzler Weights
Andrew Danowitz
Fuel Economy Sensitivity to Vehicle Mass for Advanced Vehicle Powertrains
S. Pagerit, P. Sharer, A. Rousseau
Lightweighting Impacts on Fuel Economy, Cost, and Component Losses; Aaron
David Brooker, Jacob Ward, Lijuan Wang
The EPA says that for every 100
pounds taken out of the vehicle,
the fuel economy is increased by
1-2 percent.
In conventional ICE vehicles a 10% mass reduction;
- Without powertrain re-sizing improves mpg between 1.9%-3.2%.
- With powertrain re-sizing improves mpg between 2.6%-3.4%.
Diesel engine Determination of Weight Elasticity of Fuel Economy for Conventional ICE Vehicles, Hybrid
Vehicles and Fuel Cell Vehicles Forschungsgesellschaft Kraftfahrwesen mbH Aachen Body Department
Rhett Allain - Wired
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Year
Ave
rage
Veh
icle
Mas
s /
lbs
Since 1998, the average vehicle mass has
increased by…
17lbs /yr for cars
42lbs /yr for trucks
Average Vehicle Mass 1980-2012 (NA)
5
Vehicles have increased in weight due to;
• Customer Features: Size, Options, etc.
• Safety Regulations & Features
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BIW Mass Trend
• Mass of Ford Sedan BIWs are on a decreasing trend.
• From 2007 to 2017 Ford’s average BIW reduction is 17%.
• “Snap Shot of the Industry” shows the average trending down 12.5% over the same time.
• More cost effective weight saves are required.
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• Light Weight Design Mindset
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Optimized Design: Topology Optimization
8
Full Vehicle
Component Level
System Level
• Mass savings starts at the early in the design phase by insuring that the optimal load paths are defined
• Establishing the ideal load paths allow energy transfer through the structure with the minimum amount of material and material strength
Three applications of Topology:1. Full Vehicle – focus on defining the overall load path strategy
based on vehicle level load conditions2. System – develop geometry to address specific loads within a
given system3. Component – insure the geometry at the component level is
optimized to the local events
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• Safety regulations and need for weight reduction have driven the need for higher strength steels
• Increase of up to 104% in the Average Yield Strength of Ford BIWs since 2008
Average Yield Strength
Advanced
High Strength
Steel:
DP1000
Martensitic
Steel
Advanced
High Strength
Steel:
DP600 &
DP800
Mainstream
Boron
High Strength
Low Alloy
Bake
Hardenable
Solution
Strengthened
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• Utilize all available forming processes to:
– Enable the utilization of the highest strength materials available
– Improve the geometric properties of a given part
– End goal of achieving reduced cost and mass required to achieve a given level of performance
• Current focus is on Hot Stamping, Roll Forming, and Hydro-Forming
Forming Processes and Geometry
10
F-Series: Front End and Body Side
Fusion: A-Pillar / Roof Rail & B-Pillar
Mustang: A-Pillar / Roof Rail
Edge: A-Pillar / Roof Rail & D-Pillar
Hydro-Forming
Roll Forming
Hot Stamping
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Hydro-Forming Evolution
11
31PARTS
18PARTS
20BENDS
STAMPED STEELFIRST HYDROFORM
STEEL
FIRST ALUMINUM
HYDROFORM
12PARTS
6BENDS
FRONT-END SUPER DUTY/EXPEDITION
31WEIGHT
%
– 59WEIGHT
%
–
FRONT-END SUPER DUTY FRONT-END F-150
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A-Pillar / Roof Rail: Closed Section Design
12
DP1000 Hydro-formed Tube
Gage: 2.0mm
DP1000
Gage: 2.0mm
DP1000
Gage: 1.5mm
HSLA 350
Gage: 1.6mm
HSLA 350
Gage: 1.8mm
HSLA 350
Gage: 1.8mm
Mild
Gage: 1.2mm
2014 Mustang 2015 Mustang
Replacement of complex stampings with a tubular structure enables:
• The use of higher strength steel within a reduced package
• Increased vehicle performance
• Reduced package requirement
Concept initiated on F-150 and proliferated across vehicle lines
Vehicle Material Mass Savings
F-150 DP800 6.1 kg
Fusion DP1000 4.2 kg
Mustang DP1000 3.9 kg
Continental DP1000 4.5 kg
F-150 6000 Series
Expedition 6000 Series
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• 1st Gen (production) – Max strength stamping technology available. YS=> 1000 Mpa, TS=> 1300 Mpa.
• 2nd Gen (pre-production) – Inc. YS & TS. YS=>1400 Mpa, TS=> 1800 Mpa.
• No Springback, enabling complex parts.
• Technology is rapidly expanding.
– 2016 Civic = 14% Boron (from 1%)
– 2016 Volvo V90 = 29% Boron
Boron - Hot Stamping
13
• Maximum High Strength Stamping material.
• Processing dependent.
• High Cost.
Heating
880-930°C
3 – 10 min
Stamping (600-800°C)
+ Hardening (>> 50 K/s )
Transfer
Volvo V90 ’16Civic ’13 vs. ’16
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Tailored Material Thickness
14
Tailor Rolled Blank introduced to place gage where needed to meet the performance
requirements and provide mass savings
Mass savings of 1.2 kg achieved over the conventional Hot Stamping approach.
Very costly weight savings technology
Variation of gauge allowed for the
elimination of the B-Pillar
Reinforcement
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Aluminum: Post Form Heat Treatment
15
0
50
100
150
200
250
300
350
6HS2-T81 6HS2-T82
Str
ess [
MP
a]
YS UTS
6HS2-PFHT
STAMPING
HEAT-TREAT
OVEN
BODY SHOP
PAINT
• Ford developed a novel Post Form Heat
Treatment (PFHT) cycle for 6XXX sheet alloy
(Industry-first) that results in a:
• 66% increase in Yield Strength
• 6% increase in Ultimate Strength
• PFHT is used to strengthen sheet parts for
yield-limited applications
• 14 stamped parts undergo the PFHT
operation
PFHT Process
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New Materials – 3RD Generation Advanced High Strength Steel
16
Developments in steel related to 3rd Generation Advanced High Strength Steel offer opportunities:
• Increased Yield Strength allows for gauge reduction of strength driven parts
• Yield Strength increased combined with improved ductility offer opportunities to optimize parts requiring energy absorption
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Composites - Resent Usage within Ford Motor Company
/// 17
• SMC – Multiple Applications
• Hood (FN9 Continental, Mustang, Raptor, Windstar)
• Fenders (FN9 Continental, Raptor)
• Decklids (SN95 Mustang, MKS)
• Radiator Supports
• Carbon Fiber
• New Ford GT (Body Structures and Closures)
• Wheels (Ford Shelby GT)
• Battery Box Covers (PHEV, BEV)
• Driveshaft 2013 Shelby GT
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Carbon Fiber Application Philosophy / Needs
/// 18
Philosophy
• Defining High Volume as about 100k units per year
• Considering performance line of vehicles (100 to 40k units per
year)
• Weaves have too much operator handling to be efficient for
Ford Motor Company volumes
• Applied in mixed material vehicles.
Needs
• Lower cost materials & processing
• High volume joining methods and associated processes.
• Corrosion testing correlation with real life along with corrosion
mitigation methods when used in conjunction with steel,
aluminum and/or magnesium.
• In Plant repair methods.
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Summary
/// 19
• Stronger lighter vehicles are needed.
• Ford is reduced the BIW weight faster than the industry.
• Ford is open to any and all technology required to meet Regulatory
and Customer requirements.
• We’re interested in working with Suppliers that can deliver cost
efficient weight reduction technologies.
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THANK YOU
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Electric Vehicle & Mass
Analysis of Parameters Influencing Electric Vehicle Range;
Martin Mruzek*, Igor Gajdáč, Ľuboš Kučera, Dalibor Barta
Lightweighting Impacts on Fuel Economy, Cost, and Component
Losses; Aaron David Brooker, Jacob Ward, Lijuan Wang
A similar relationship between power required or range and vehicle mass exists for electric vehicles
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B-Pillar: Closed Section Design
23
Reinf Center
Hinge Pillar
1.4 mm Boron
Reinf Ctr
Bdy Plr - Upr
1.0 mm Boron
Plr Bdy Lock Inr
1.2mm Boron
Tube – Front Body Pillar
1.4 mm DP1000
Tube – Rear Body Pillar
1.8 mm DP1000Bracket Center Pillar Upper
1.2 mm DP800
Hinge Reinforcement Outer
1.75 mm DP800
Plr Bdy Lock Inr
0.75 mm HSLA 340
Closed section concept was extended to the B-Pillar for the Fusion enabling:
• Elimination of large press hardened parts
• Use of AHSS
• Reduced intrusion during side impact
• 6 kg mass reduction
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SUSTAINABILITY“GREEN”
SAFETY “SAFE”
DESIGN “SMART”
Drive green. Drive safe. Drive smart.
Drive quality.
TechnologyLeadership Commitments
• Design leadership on each new program
• Leadership in interior comfort / convenience, infotainment technology
• Global platforms with right proportions
• Improve emotional appeal
• Leadership safety technology / feature content
• Achieve public domain targets and 3rd party recommended buys
• Breakthrough features for family safety
• Leadership in fuel economy with every new or significantly refreshed entry
• More renewable, recycled materials
• Vehicle light weighting
LEADERSHIP FOUNDATION “QUALITY”
Sustainability – Clear Technology Priorities
Our leadership commitments
around Quality, Green, Safe and Smart
consistently guide our product
development team priorities every day
24
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Structural Castings
Typical Steel Design Die Cast Design
5-7 Stampings welded into one assembly with
welds nuts and studs
1 Casting
C2 DesignAn industry wide shift from stamped shock towers to cast aluminum
components has begun.
25
Expected benefits:
• Reduced component mass
• Increase local and vehicle level stiffness
• improved dimensional accuracy through part integration
• Efficient attachment integration – elimination of brackets.
Going forward . . .
Automotive aluminum castings and market trends
Norberto F. Vidaña Market Intelligence Aluminum
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Regulation Changes
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Extrusions
27
Advantages Afforded by Extrusions:
• Freedom to place material where you need it
• Addition of internal ribs / reinforcements to
improve the effectiveness of the design
section
• Closed section without discrete connection
pointsFront Header Section
Front Header
Rocker Reinforcements
Shotguns1
Extruded Applications on the F-150
Case Study: Front Header
Stamped to Extruded
Part Reduction: 3 to 1
Mass Reduction: 2.9 kg
A-Pillar / Roof Rail1
Lower Rad Support
1 Additional geometry changes achieved through bending and hydro-forming processes
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Tailored Material Properties
28
Typical
mechanical
properties:
Rm = 550 Mpa
Re = 400 Mpa
Ɛ(A5) > 20%
Typical
mechanical
properties:
Rm = 1450 Mpa
Re = 1100 Mpa
Ɛ(A5) > 6%“Soft”Hard area
Transition zone
from soft to hard
area
• Rails were shortened for donor vehicle to provide correct vehicle
proportions
• Mass of the vehicle increased over the donor vehicle
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Mixed Material BIW
29
The Original
Aluminum Hood
Wood Structural Frames
Steel Panels
The Future . . .