Advanced High Strength Steel Technology in the Ford 500 .../media/Files/Autosteel/Great Designs...
Transcript of Advanced High Strength Steel Technology in the Ford 500 .../media/Files/Autosteel/Great Designs...
Advanced High Strength Steel Technology in the Ford 500 and
Freestyle
Michael J. LeeFord Motor Company
March 9, 2005
w w w . a u t o s t e e l . o r g
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GDIS Presentation Michael J. Lee
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
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Ford 500
“Redefining the North American sedan is a tall order…We took a look at the attributes that make crossovers popular – like high-package ‘command’ seating – and sought to deliver some of those qualities in a sedan. While the industry tries to create new car-based crossovers, the Ford Five Hundred stands alone as the first crossover-based car.”
Phil Martens Group Vice President Product Creation Ford Motor Company
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Ford Freestyle
“Freestyle is the crossover done right. We didn’t try to adapt an existing minivan or sport utility platform. Freestyle is built from the ground up as a crossover with class-leading spaciousness, seven-passenger comfort, versatility and all-wheel-drive capability. And through it all, Freestyle will deliver with the value that defines it as a Ford...”
Phil Martens Group Vice President Product CreationFord Motor Company
09-MAR-2005 Ford Confidential
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Selling Features
Ford 500• Highest Seating position of
any sedan.• Confident and commanding
driving experience• Unparalleled convenience
and storage • Effortless entry and exit• Exceptional interior
roominess• Safety and confidence of
AWD
Ford Freestyle• Carry 7 adults in total comfort• Totally flat load floor with 2nd
and 3rd row seats folded down• Unparalleled convenience and
storage• Most flexible/versatile interior• Effortless entry and exit• AWD for safe and confident
driving.
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
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Presentation Scope / Purpose
• Body in White on the 2005 Ford 500, Freestyle, and Mercury Montego
• No Breakthrough Technology presented, but an Implementation History, Success Story, and Lessons Learned on one Vehicle Platform
• Information Sharing
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
09-MAR-2005 Ford Confidential
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Building Blocks
• Architecture and Energy Management Strategy evolved from Volvo P2X Platform.
• Extensive global sharing of information and technology.
• Volvo and Ford Europe implemented DP600 in 1990’s.
• Volvo had been utilizing DC Welding vs. Ford NA AC Welding.
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Major Implementation Challenges
• Freestyle and 500 share Platform – Sedan and Cross-over. Common Front Structure, Common Front Floor, Common Bill of Process
• Ford NA did not have any approved NA Suppliers for DP600. Required concurrent implementation and Certification processes
• MFDC Welding was viewed as a key enabler for implementing DP600, but was not part of Ford NA Toolset
• Production Draws at CP Prototype Build
• Rising Steel Prices, Fuel Economy Targets, and a goal of Outstanding Safety Performance
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
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Stress/Strain curves
Engineering Strain (%)
0 10 20 30 40 50
Eng
inee
ring
Stre
ss (M
Pa)
0
200
400
600
800
Mild SteelHSLA (50F) DP600TRIP600
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Dual Phase vs. HSLA
Relative Performance
DP600 HSLAFormability ++ +Weldability ++ +++Fatigue +++ +++Energy Absorption +++ ++Bake Hardening +++ +Work Hardening +++ +
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Dual Phase vs. HSLA
Strength
Component Material Strength
0
100
200
300
400
500
600
HSLA350/450
DP350/600
Yield Strength
Sheet YSWork-HardeningBake-Hardening
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Material Usage by Mass on Ford 500
14%
12%
0%15%
59%
HSLA250
HSLA350
HSLA550
DP600
Mild Steel
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Ford 500
Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 / Bottom
HSLA 250Outer: Top DP600 / Bottom Mild Steel
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Ford 500
Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 /
Bottom HSLA 250Outer: Top DP600 / Bottom Mild Steel
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500 Safety Success – Frontal
5 – Star for Driver and
Passenger!!!
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Ford 500 – Load Path - Frontal
TWB HSLA Front RailDP600 Dash xmbrsDP600 Y-Brace
DP600 Side Member
HSLA Tunnel
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Ford 500 – Load Path -Frontal
HSLA Shotguns/Rails
HSLA Cowl Sd Inr Pnl
Upper / Lower Load Path
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500 Safety Success – Side Impact
5 – Star for Front Seat and Rear Seat
without Side Airbags!!!!!
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Ford 500 – Load Path – Side Impact
TWB DP600 B-Plr Inr/OtrHSLA 550 Ctr Roof BowHSLA CrossmbrsDP600 Side Mbr
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Ford Freestyle
Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 /
Bottom HSLA 250Outer: Top DP600 / Bottom Mild Steel
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Ford Freestyle
Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 /
Bottom HSLA 250Outer: Top DP600 / Bottom Mild Steel
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Ford Freestyle – Bottom View
Unique Reinfs for 2nd
Row Seats vs. 500
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Futured Safety Performance
Both 500 and Freestyle are already:
• Designed to meet new FMVSS 208 front impact
• Designed to meet upcoming FMVSS 301 rear impact
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Body Stiffness Vs. Competition
CD338 ADV
M azda 6M azda 6 Ford D219 CP1
Ford D258 CP1
M ercury Sable
Audi A8Toyota Camry
Honda Accord
Ford TAURUS
Lexus RX300
BM W 328i
BM W X5
Toyota Avalon
Toyota Celica
BM W 330i Coupe
Toyota Camry
Toyota Highlander
Lincoln LS
M azda 6
Honda Civic
0
4000
8000
12000
16000
1992 1994 1996 1998 2000 2002 2004 2006 2008
MY
N/m
m
500Freestyle
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
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Formability – Lessons Learned
• DP steels have an excellent work hardening coefficient, and hence, are difficult to re-draw
• Final part geometry should be obtained in initial draw
• DP steels require higher blank holder forces than HSLA steels. (20-30% higher than HSLA 350.)
• Drives higher die construction costs, revised / upgraded die materials, and revised press tonnage strategy
• Incremental die tryout time required to manage spring-back corrections
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Welding Considerations
• Increasing stackup thickness ratios due to the use of thinner gage components.
• Joint spring back for short hold times during weld cycle.
• Weld quality verification – acceptance criteria• Weld button formation vs. interfacial
separation.• Ergonomics in teardowns.
• Welding specifications and standards.
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Welding – Lessons Learned
• No issue with interfacial separation, even with the use of an air hammer and chisel.
• Difficulty with thin-thick-thick stackups (more than typical).
• Longer weld time has been necessary.
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Welding Requirements
• Dual-headed, frequent tip dressing.• Adaptive weld controls may be required as we go
beyond DP600. Technology is currently being proven out.
• Additional weld teardowns – AHSS in a sub-assembly will increase the number of non-pryable welds.
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Agenda
• Overview of Products
• Presentation Scope / Purpose
• Assumptions / Challenges
• Materials and Application
• Formability and Welding Lessons Learned
• Conclusions
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Conclusions / Success Enablers(Slide 1 of 2)
• Use of AHSS enabled weight efficiency and world class performance
• Use of global architecture sharing
• Integration of manufacturing/product development teams
• Intensive use of CAE tools for safety, NVH, durability - and stamping FEA tools
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Conclusions / Success Enablers (Slide 2 of 2)
• TWB usage in front rails and B-Pillar construction
• MFDC welding implementation
• Early and intensive supplier involvement
• Intensive dimensional control strategy –including production draws and production assembly tooling at CP build
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Acknowledgements
• Paul Schurter / Sean Martin - Dofasco
• Todd Mueller – Ford Body Structures
• Ted Coon – Ford VOGO – Welding
• Dr. Don Jordan – Ford Materials
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