ensuringmanufacturing infrastructurereadiness( · audia8$
TRANSCRIPT
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Ensuring Manufacturing Infrastructure Readiness
Dr. Paul E. Krajewski General Motors Company
GALM 2013
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Outline Define Scope of Problem Key Questions Material Product Development Forming Assembly / Joining Painting Execution Summary
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Back to the Future
1909 Ford Model T Touring Car
Aluminum Hood, 1915 Model T
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It is difficult to define manufacturing
lightweighting approaches.
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Audi A8
http://media.windingroad.com/autos_db/lists/3-‐Aluminum_Space_Frame_jpg_667x667_q100.jpg
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Plastics Omnium
http://www.scoop.it/t/evolution-‐et-‐inovation-‐auto
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MIXED MATERIALS SOLUTIONS
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ATS Material Selection Mild Steel Bake Hardenable HSLA Dual Phase Martensitic PHS Al
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BMW i3 & i8
Carbon Fiber
Aluminum
http://www.eurocarnews.com/media/pictorials/1483/7130.jpg
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Audi Mixed Materials
Aluminum Carbon Fiber
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Key Light-‐weighting Questions
Need to define overall strategy What vehicle segment / price point / volume? What is the value of mass on the program? Global or regional execution? Which materials and parts? Where will parts be produced? Make vs. Buy What assembly / joining technique will be used?
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Material
Raw material availability geography Conversion to sheet / extrusion / ingot Preparation for forming pretreatment Blanking vs. Coils
http://en.wikipedia.org/wiki/File:Extruded_aluminium_section_x3.jpg
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Key Material Issues PHS
Prototype infrastructure Material suppliers with Zn coating
Aluminum Heat treat capacity Structural casting infrastructure
Magnesium Limited supply base for low cost sheet and HPDC 90% of material produced in China
Composites Low density SMC Class A / Painting Dimensional stability / fit
Carbon Fiber Overall Industry capacity low. North American supply base limited.
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Lightweight Material Capacity
Aluminum 2012 NA capacity for heat treated Al sheet 90kT. An AIV with 400,000 APV requires 90 kT.
Carbon Fiber A carbon fiber intensive body and closures at 200,000 APV would consume global fiber capacity.
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Product Development Issues
Overall lack of experience with lightweight materials. Lack of design for manufacturing (DFM) information. CAE database for materials and joints.
Opportunity for industry collaboration
Develop best practices. Acoustic management.
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Primary Forming PHS
Hot forming lines required Typically done in supply base
Aluminum Can use existing steel infrastructure Need more dies (5-‐6) different lubricants. Scrap segregation
Magnesium Requires thermal assisted forming Die casting infrastructure limited.
Composites SMC supply base limited. Long cycle time Improved formability compared to steel/Al
Carbon Fiber North American supply base limited Long cycle time
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Need to develop new processes to enable mixed material vehicle executions.
Decide whether performing in-‐house or at suppliers Accurately forecast usage to assure capacity
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Form Press
Form Tool
Destack Robot
Blank Stack
Blank PresentationFixture
Blank Pre-Heater
Press Automation
Exit Conveyance
Operator Station &
Ergonomics
Hot ToolCleaning Robot
Cooling Fixture
Location
Form Press
Form Tool
Destack Robot
Blank Stack
Blank PresentationFixture
Blank Pre-Heater
Press Automation
Exit Conveyance
Operator Station &
Ergonomics
Hot ToolCleaning Robot
Cooling Fixture
Location
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Secondary Forming Trimming Clinching Hemming
BENDING MAGNESIUM FOR AUTOMOTIVE
AZ31 Magnesium
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Assembly / Joining PHS
Need new welding, fastening and bonding techniques
Aluminum Spot welding compatible with steel? Riveting Adhesive bonding without pretreatment
Magnesium Need heated clinching / fastening Corrosion isolation.
Composites/Carbon Fiber Closure assembly at Tier supplier Need bonding / fixturing experience Surface effects / read-‐through
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Painting
Aluminum and PHS can be processed through conventional paint lines. Al / Steel mix can require varying phosphate bath chemistry Paint bake temperature can affect aluminum properties and will affect composites. Magnesium need to be coated prior to painting/assembly Composites usually painted offline and installed in General Assembly.
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The easiest approach to enabling the use of lightweight materials is a dedicated plant.
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Bowling Green Assembly
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Hydroformed Al Frame Rails
Carbon Fiber Floor Pan
Mg Engine Cradle
Ti Valves and Connecting Rods
Mg Roof Frame Hydroformed Al Roof Bow
Corvette Z06
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Corvette Stingray
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Aluminum Frame
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Tube Hydroforming
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Composite Painting
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Corvette Assembly
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Camaro
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Camaro ZL1
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Global Multi-‐Plant Platform
Key Issues/Questions: Common execution or regional variation Model changeover strategy Are multiple architectures built in same plant Dedicated or flexible body shop
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Summary
The increased use of lightweight materials will require capital investment and increased piece cost. Impact can be minimized with clear strategy and long term vision. A long term strategy is essential to making sure the value chain is ready for execution.