casting weight reduction by die design topology
TRANSCRIPT
CASTING WEIGHT REDUCTION BY DIE DESIGN TOPOLOGY OPTIMISATIONM.Sc.Aircraft & Mechanical Engineer Kadir Akcan
• Company Profile of Ford Otosan A.Ş
• Project Aim
• Manufacturing of Sheet Metal Parts and Project Aim
• Sheet Metal Stamping Cycle
• Ford Die Design Standards (WDX)
• Optimisation Phases
• Manufacturing Phases
• Test Phases
• Results
CONTENTS
LOCATIONS OF FORD OTOSAN A.Ş
İnönü Plant - 1982
Gölcük Plant - 2001
Yeniköy Plant - 2014
Sancaktepe Parts Distribution Center- 1998
Black Sea
İstanbul PDC
HondaHyundai
Toyota
Tofaş-FiatRenault
Kocaeli PlantSea of Marmara
Inonu Plant●Eskisehir
●Bursa
●İstanbul●Kocaeli ●Sakarya
Automotive industry intensity: Both OEMs, Manufacturers are located in a 110 km radius circle centered on the Kocaeli Factory.
Sancaktepe Engineering Center- 2015
Industrial Center of Turkey: Marmara Region
2001
2007
FORD TRANSIT, BEST-SELLING VAN IN THE WORLD
Chassis Cab Van Minibus
Longest-running model in Ford of Europe’s product range ~ 9 million units produced globally since its launch in 1965 Manufactured by Ford Otosan since 1967 Ford Otosan is the lead manufacturing plant of Transit globally
Loading Capacity: 3.3 tons – 4.7 tons
Loading Capacity: 9.5m3 - 15.1 m3
Seating Capacity:11+1 / 17+1
FORD CUSTOM
Ford Otosan is the single global source of Ford Custom
Launched in October 2012
First vehicle in its segment to achieve a maximum five-star Euro
NCAP rating
Loading Capacity:5.9 m3 - 7.2 m3
Transit Custom (Commercial)Tourneo Custom (People Mover)
Long and Short Chassis 8+1 Seating Capacity
4.97m – 5.34 m
Loading Capacity:6.8 m3 - 8.3 m3
FORD COURIER
Ford’s first vehicle in the compact van segment
Ford Otosan is the single global source of Ford Courier
Launched in May 2014
Tourneo Courier(People mover)
Transit Courier Combi Van(Commercial)
Transit Courier Van(Commercial)
FORD TRUCKS
Manufactured at Ford Otosan’s İnönü Plant since 1983
Road truck, construction and tractor series available
Cargo 1846T – 2013 International Truck of the Year 3rd place
Distribution Trucks
Long Haulage
Construction Trucks
4x2 Tractor and 6x2 Full Trailer are the main applications.
Available in E3&E5 and E6 emission levels with 13L Ecotorq engine generating power 420 and 480 PS
Mainly used for local distribution and municipality (special purpose vehicles)4x2, 6x2, 8x2 applications.
Available in E3&E5 and E6 emission levels with 9L and 13L Ecotorq engine generating power 330 and 420 PS
Tippers, Transmixers, Cement Pumps. 6x4, 8x4, 4x2, 6x2 and 8x2 applications.
Available in E3&E5 and E6 emission levels with 9L and 13L Ecotorq engine generating power 330 and 420 PS
TRACTOR ROAD TRUCK CONSTRUCTION
ECOTORQ ENGINE FAMILIY
Available in 9L 330PS and 13 L 420 to 480PS
Environmentally Friendly Euro 6 Emission Levels
Turbocharger with Variable-Geometry
2500 bar Common-Rail Fuel Injection System
Specially Coated Pistons
Smart Charging Alternator
• f(x): Objective function :Minimize Compliance• gi(x): Constraints :Volume Fraction (<%30)
:Displacement (<1mm):Stress (220 Mpa)
• x: Design variables :Density of elements
Minimize: f(x)
Subject to : g(x) ≤ 0
PROJECT AIM
?
F
TOPOLOGICAL OPTIMSATION
DRAWOP20 TRIMOP30 TRIMOP40 FLANGEOP50
• Automative parts manufacture about 3 or 4 die• Every die roughly 25-35 ton • Project aims to reduce die weights %20
MANUFACTURING OF SHEET METAL PARTS & PROJECT AIM
SHEET METAL STAMPING CYCLE
1.Ready to stamping 2.Cramping
3.Forming (Drawing) 4.Openning the press
Top Press RamUpper Die
Draw Cavity
Sheet Metal
Binder
Gas Springs
Lower Die
Lower Press Ram
• Die Construction• Rib Thickness• Rib Distances• Air Pins• Die Automation• Electiral Equipment• Die Matarials• Screw, Dowels• Air Cylinders
FORD DIE DESIGN STANDARDS (WDX)
Helps to design new sheet metal die according to specs Design specs determined with experienced and calculations Some WDX title like below;
Rough Die Design
Conventional Die Design
Die Design According to WDX
Rib Thickness Rib Distances Geometrical Construction
According to WDX Standards.
CONVENTIONAL DIE DESIGN
OPPORTUNITIY
RibsWeight Reduction
Pockets
PILOT PANEL AND FORMABILITY ANALYSIS
Sheet Metal Analysis
New H625 Cargo Back Panel DieSelected as Pilot Part of Project
Obtained Contact Pressures
OPTISTRUCT DESIGN SPACE
Non design space
Non design space
Design space
Only bottom side of dies selecting as playgraund
OPTISTRUCT INPUTS & OUTPUTS
Lower Die Optistruct Result Upper Die Optistruct Result
• Contact pressures transfered to Optistruct with script code• Design and non-design spaces defined in Optistruct• Objective function and constrains determined in OptistructOutputs
• Ribs linked for die design iteration
CHECKING THE OPTIMISATION RESULTS BY CAE
DynamicAnalysis
StaticAnalysis
Results must be OK, if not die design will be revised
CHECKING THE OPTIMISATION RESULTS BY CAE
Displacements
Maximum displacements results obtained
ANALYSIS WORK FLOW SUMMARY
SHEET METAL SIMILATION DIE
DESIGN-1
CAE STATIC CHECK
OPTISTRUCT
INPUTS• Panel data
• Material Specs
OUTPUTS• Press force
• Contact Pressure
• Feasibility analysis
INPUTS• Solid Design without ribs
• Contact pressures
• Volume precentage
• Max. allowed displacement
OUTPUTS• Material distribution
DIE DESIGN-2
CAE DYNAMIC CHECK
INPUTS• Design with ribs
• Contact pressures
OUTPUTS
• Von Mises stress
• Displacements
INPUTS• Design with ribs
• Press speed
• Material specs
• Contact parameters
• Boundary conditions
OUTPUTS
• Contact pressures
• Von Mises stress
• Displacements
MANUF. PHASE
CAE TUNE UP
NOKOKOKNOK
STRAIN GAGES
OUTPUTS• Real strain values
INPUTS• Panel data
• Material Specs
• Press Specs
OUTPUTS• Solid die Design
• No weight reduction
INPUTS• Panel data
• Material Specs
• Press Specs
• Optistruct Results
OUTPUTS
• Die design have ribs
• Have weight reduction
OUTPUTS
• Casted and machined die
• Try-out
BEYOND STANDARDS WITH OPTIMISATION
Conventional Die Design(Cargo H566)
Optimised Die Design(Cargo H625)
Bottom View of Upper Die
OPTIMISED OK TO CAST DESIGN
Upper Die View
Lower Die View
MANUFACTURING PHASES
FOAM MODEL CASTING
ASSEMBLYMACHINING
TEST PHASE
• Totally 48 strain gages adapted to die surfaces• Dynamic strains collected from die with strain gages• Dynamic forces collected from press
RESULTS
• Press forces, strain values and CAE outputs will comparednext weeks.
Technical Results
Fiancial Results
Questions?