SAE PT-170-2015 The Multi Material Lightweight Vehicle (MMLV) Project (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、The Multi Material Lightweight Vehicle (MMLV) ProjectOther SAE books of interest: Plastics Application Technology for Lightweight Automobiles By Sudhakar Marur (Product Code: R-415) Automotive Lightweighting Using Advanced High-Strength Steels By Paul E. Geck (Product Code: R-431) Design of Automoti

2、ve Composites By Charles Lu and Srikanth Pilla (Product Code: PT-164) Lightweight Magnesium Technology 2001-2005 By Thomas Ruden (Product Code: PT-131) For more information or to order a book, contact: SAE INTERNATIONAL 400 Commonwealth Drive Warrendale, PA 15096 Phone: +1.877.606.7323 (U.S. and Can

3、ada only) or +1.724.776.4970 (outside U.S. and Canada) Fax: +1.724.776.0790 Email: CustomerServicesae.org Website: books.sae.orgThe Multi Material Lightweight Vehicle (MMLV) Project By Timothy Skszek, Jeff Conklin - Magna International Matthew Zaluzec, David Wagner - Ford Motor Company project co-fu

4、nded by US Department of Energy Warrendale, Pennsylvania, USA Copyright 2015 SAE International eISBN : 978-0-7680-8224-1iv Copyright 2015 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or b

5、y any means without the prior written permission of SAE International. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. Library of Congress Catalog Number 201594140

6、2 SAE Order Number PT-170 http:/dx.doi.org/10.4271/pt-170 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and

7、neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or

8、 other professional services. If such services are required, the assistance of an appropriate professional should be sought. ISBN-Print 978-0-7680-8223-4 ISBN-PDF 978-0-7680-8224-1 ISBN-epub 978-0-7680-8226-5 ISBN-prc 978-0-7680-8225-8 To purchase bulk quantities, please contact SAE Customer Service

9、 e-mail: CustomerServicesae.org phone: +1.877.606.7323 (inside USA and Canada) +1.724.776.4970 (outside USA) fax: +1.724.776.0790 Visit the SAE Bookstore at books.sae.org 400 Commonwealth Drive Warrendale, PA 15096 E-mail: CustomerServicesae.org Phone: +1.877.606.7323 (inside USA and Canada)+1.724.7

10、76.4970 (outside USA) Fax: +1.724.776.0790v Table of Contents Acknowledgments . vii Introduction ix DOE Focuses on Developing Materials to Improve Vehicle Efficiency (2015-01-0405) 1 Schutte, Carol: Department of Energy Vehicles Technology MMLV: Project Overview (2015-01-0407) . 9 Timothy W. Skszek,

11、 Magna International; Matthew Zaluzec, Ford Motor Company; Jeff Conklin, Magna International; David Wagner, Ford Motor Company BIW Design and CAE (2015-01-0408) . 17 Jeff Conklin, Randy Beals, Zach Brown, Magna International MMLV: Door Design and Component Testing (2015-01-0409) . 25 Larry Plourde,

12、Magna International; Michael Azzouz, Jeff Wallace, Ford Motor Co.; Mari Chellman, Magna International MMLV: Lightweight Interiors Systems Design (2015-01-1236) 35 John Jaranson, Ford Motor Company; Meraj Ahmed, Eicher Engineering Solutions MMLV: Chassis Design and Component Testing (2015-01-1237) 43

13、 Xiaoming Chen, Ford Motor Company; Jeff L. Conklin, Robert M. Carpenter, Magna International; Jeff Wallace, Cynthia Flanigan, David A. Wagner, Vijitha Kiridena, Ford Motor Company; Stephane Betrancourt, Sogefi Group; Jason Logsdon, NHK Spring Group MMLV: Aluminum Cylinder Block with Bulkhead Insert

14、s and Aluminum Alloy Connecting Rod (2015-01-1238) 53 Cliff Maki, Kevin Byrd, Bryan McKeough, Ford Motor Co.; Robert G. Rentschler, Ford Casting Operations; Brian J. Nellenbach, Rick L. Williams, James M. Boileau, Ford Motor Co MMLV: Carbon Fiber Composite Engine Parts (2015-01-1239) 65 Neal J. Core

15、y, Mark Madin, Rick L. Williams, Ford Motor Co.vi MMLV: Automatic Transmission Lightweighting (2015-01-1240) . 71 James Kearns, Soon Park, Ford Motor Co.; John Sabo, Dusan Milacic, Magna International MMLV: Corrosion Design and Testing (2015-01-0410) 83 Kevin Smith, Ying Zhang, Magna International M

16、MLV: Vehicle Durability Design, Simulation and Testing (2015-01-1613) . 91 Nikhil Bolar, Thomas Buchler, Magna International; Allen Li, Jeff Wallace, Ford Motor Co. MMLV: Crash Safety Performance (2015-01-1614) 99 Yijung Chen, Derek Board, Omar Faruque, Cortney Stancato, James Cheng, Ford Motor Comp

17、any; Nikhil Bolar, Sreevidhya Anandavally, Magna International MMLV: NVH Sound Package Development and Full Vehicle Testing (2015-01-1615) 105 Yuksel Gur, Ford Motor Company; Jian Pan, Autoneum North America Inc; John Huber, Jeff Wallace, Ford Motor Company MMLV: Life Cycle Assessment (2015-01-1616)

18、 .113 Lindita Bushi, Life Cycle Assessment Consulting; Timothy Skszek, Magna International; David Wagner, Ford Motor Company MMLV Project Team . 127vii Acknowledgements Magna International Inc. and Ford Motor Company would like to acknowledge the efforts and contribution of their employees represent

19、ing Magna International, Vehma Engineering, Vehma Prototype, and Ford Research & Advanced Engineering. Further, we acknowledge the U.S. Department of Energy, Vehicle Technologies Office for financial support and leadership. This material is based upon work supported by the Department of Energy (DOE)

20、 National Energy Technology Laboratory (NETL) under Award Number number DE-EE0005574. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither Magna International, Ford Motor Company, the United States Government nor any agency thereof, nor any o

21、f their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference here

22、in to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed her

23、ein do not necessarily state or reflect those of the United States Government or any agency thereof. Such support does not constitute an endorsement by the Department of Energy of the work or the views expressed herein. Additionally, the MMLV team acknowledges the efforts and creativity of all the s

24、uppliers who contributed to the project. We look forward to working together to reduce the costs and risks of these technologies for future vehicles. Body Structure Sound Package Body Joining Laminated Glazing MAGNA Vehma Prototype PPG Automotive Coatings Autoneum North America, Inc. Henrob E-Jot Hu

25、ck Alcoa Fastening Lord Corning Incorporated SALGGLAS, ZRt. Engine Body Castings Tires Polycarbonate Glazing Fraunhofer USA Conner Engineering Anderson Global ASK Chemicals Wolverine Bronze Manitowoc Foundry Hexion BASF Montaplast WGS MAGNA - Powertrain Engineered Performance Materials Federal Mogul

26、 COMAU MAGNA Cosma Castings Keronite Michelin North America, Inc. SABIC Front Subframe Front Seats Aluminum Wheels Door Hinges MAGNA Cosma Casting MAGNA Promatek Sapa Extrusions Americ Eicher Engineering Solutions Maxion Wheels Multimatic Inc. Transmission Instrument Panel Carbon Fiber Wheels Glazin

27、g Adhesive Line Precision, Inc. MAGNA Powertrain Eicher Engineering Solutions Carbon Revolution Pty Ltd. Dow Automotive Systems Sika Steel Springs and Stabilizer Bars Composite Springs Brake Rotors Door Seals NHK Spring Group Sogefi Group Crescent Pattern Metro Technologies Midwest Thermal Spray Coo

28、per Standard 3M Corporation Supplier AcknowledgementPhoto Courtesy of Ford Motor Companyix Introduction Swamy Kotagiri Chief Technical Officer, Magna International The Department of Energy funded Multi Material Lightweight Vehicle (MMLV) research project provided a great opportunity for Magna Intern

29、ational to collaborate with our long-time customer Ford Motor Company on an issue that is challenging for our entire industry lightweighting. That is why we set out to address the mass reduction potential and environmental benefit of lightweighting a C/D segment passenger vehiclewhile maintaining oc

30、cupant safety, vehicle dynamics and NVH characteristics relative to the 2013 Ford Fusion baseline vehicle. The MMLV project approach included setting mass and performance targets associated with each of the major subsystems and full trimmed vehicle model, enabling the Magna and Ford design teams to

31、engineer the vehicle subsystems in parallel, prior to conducting full vehicle durability, fatigue and safety performance. The project scope included the manufacture of seven (7) prototype vehicles, enabling a limited number of component- and vehiclelevel physical tests The design strategy to maintai

32、n the vehicle hard points of the baseline C/D segment vehicle provided the opportunity to integrate carry- over parts and assemble fully functional drivable prototypes for testing and evaluation. The total project including engineering, prototype build and testing took place within a 24 month timefr

33、ame. A lifecycle assessment (LCA) was conducted by a third party LCA expert, comparing the cradle-to-grave environmental impact between the MMLV and 2013 Ford Fusion over the useful life of 250,000 km (155,000 miles). The results exceeded our expectations including clear advantages in terms of globa

34、l warming potential and the use of energy. The MMLV project shows the potential benefits of combining lightweight vehicle technologies and a downsized, high-output engine to reduce greenhouse gases and total energy. The MMLV manuscripts presented at the 2015 World Congress and contained in this book

35、 provide a technical baseline relative to the lightweighting study conducted by Magna and Ford. While this is a research prototype, we believe the MMLV points the way to a more sustainable future and we are working diligently to make these lightweight technologies affordable for high volume producti

36、on. Dr. Ken Washington, VP Research and Advanced Engineering, Ford Motor Company The MMLV research project was one of my introductions to Ford. I first was exposed to the project at a technical fair in June 2014 two months before I joined Ford Motor Company. Coming from a background in aerospace, I

37、was impressed with the creative solutions the MMLV presents to the weight reduction challenges for future cars and trucks. From the selected use of the highest strength steel, through the use of aluminum sheet extrusions and castings, to the judicious use of magnesium and composite materials, the MM

38、LV demonstrates what is technically possible for lightweight solutions. Collaboration is the key to success. With the U.S. DOE as a 50% funding partner we investigated, developed, built, and tested novel lightweight components and systems at a reduced risk. In partnership with Magna International, t

39、he team touched every area of the car looking for weight saving opportunities. The MMLV project supplied a wealth of information on what can be leveraged in our tool box as we develop future cars and trucks. The MMLVs goal was to investigate how to design and build a mixed-materials, lightweight veh

40、icle that could potentially be produced in high volume, while providing the same level of safety, durability, and toughness that our customers expect from all Ford vehicles. The MMLV explored using the right mix of materials for each application in the vehicle. The project reduced the weight of the

41、MMLV, which is the size of a Fusion, to the weight of a Fiesta and enabled the use of a one-liter EcoBoost engine to further reduce weight and improve fuel economy. The team delivered fantastic results. This fourteen-paper volume from the 2015 SAE World Congress documents the designs and test result

42、s from the MMLV project. As the costs for these lightweight designs reduce I expect to see these MMLV technologies in our future cars and trucks. A focus on light-weighting will be fundamental to our industry for years to come. Through the MMLV, and other research projects, we are investigating many

43、 advanced materials applications as potential solutions for weight reduction in our vehicles. 1 Abstract The U.S. Department of Energy Vehicles Technology Office developed requirements and identified technology gaps for lightweight and propulsion materials for light-duty and heavy-duty vehicles. Thi

44、s paper provides examples of research under development that address the highest priority technology gaps. These examples are synergistic with the Multi-Material Lightweight Vehicle demonstration project, which will be covered in detail in subsequent papers. The purpose of this paper is to show othe

45、r developments in progress that have the potential to help address technology gaps identified by the demonstration project. Introduction Transportation applications account for two-thirds of U.S. petroleum consumption 1. More than 240 million (M) vehicles are on U.S. roads, consuming approximately 8

46、5% of U.S. transportation petroleum. Reducing our reliance on petroleum contributes to greater economic and energy security as well as providing responsible stewardship of the environment. Reducing U.S. dependence on oil and reducing emissions of greenhouse gases are goals of the U.S. Department of

47、Energy (DOE) Vehicles Technology Office (VTO). To reduce U.S. consumption of petroleum, DOE is focusing on alternate fuels, electrification, and significantly improving vehicle fuel efficiency. The materials area in the VTO seeks to increase vehicle efficiency by cost effectively reducing the weight

48、 of the vehicle while maintaining performance and safety requirements, and to enable increasing the efficiency of the powertrain by: Enhancing properties of advanced high strength steel, aluminum, magnesium, and carbon fiber composites Developing joining technologies to enable multi-material design

49、and manufacturing Developing integrated modeling and computation tools to enable rapid design and development with lightweight materials Developing propulsion materials with superior properties to enable engines to operate under more demanding and higher efficiency regimes DOEs investment strategy in lightweight materials 2 focuses on those structural materials with significant weight reduction potential. In particular, this paper discusses work regarding magnesium, advanced high strength steels, and carbon fiber composite. DOEs strategy also encompasses c