Steel Application in the 2004 F-150 Body in White

Steel Application in the 2004 F-150 Body in White

Steel Application in the 2004 F-150
Body in White
Paul Elia & Dave Brzenchek
2004 F150 Body Structure Supervisors
Ford Motor Company
www.autosteel.org
2004 F-150 Family
www.autosteel.org
2004 F-150 Awards
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2004 North American Truck of the Year
2004 Truck of the Year, Motor Trend Magazine
Truckin’ Magazine Truck of the Year
2004 Truck of Texas (Texas Auto Writer’s Association)
2004 Detroit News Truck of the Year
The Year’s Best Pickup, USA Today
2004 Canadian Truck of the Year, Automobile Journalists Association
of Canada (AJAC)
Car and Driver Magazine 2004 5Best Trucks - Best Pickup (March
2004 issue)
Motor Week Magazine 2004 Driver’s Choice Award, Best Pickup
Popular Science 2003 Best of What’s New Grand Award
Top Pick of 2004 Trucks, AMI Auto World Magazine
Money® Magazine’s 2004 Car Guide - Best Pickup
Kelley Blue Book Best Redesigned Vehicle for 2004
www.autosteel.org
2004 F-150 Awards
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American Woman Road & Travel Pickup Truck of the Year: Most
Athletic
FAMA Magazine Truck of the Year
Money® Magazine Best New Truck for 2004 (review of all new
pickups)
Top Ten Tow Vehicles, Go Boating Magazine
2004 People’s Choice Truck of the Year
Urban Truck of the Year, On Wheels Inc.
eMOTION! REPORTS.com Truck of the Decade
Best Pickup, Automundo Magazine (America’s number-one Spanish
language automotive magazine)
Auto Journalists Association of Canada (AJAC) Best New Pickup
Award for 2004
2004 Automotive Showcase People’s Choice Award, Winnipeg Free
Press
www.autosteel.org
Agenda
• BIW Design
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Targets
Steel Usage
Critical Sections
Tailor Welded Blank Bodyside
Adhesive Applications
Sound Transmissibility
Crash
BIW/Vehicle Performance
Summary
www.autosteel.org
2004 F-150 BIW Design Targets
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PAL’s Strategy
BIC Global Bending:
- Target 7000 N/mm
- BIC Competitor 6713 N/mm
BIC Global Torsion
- Target 800 KNmm/Rad
- BIC Competitor 800 KNmm/Rad
BIC Body Air Leakage/
- 58 CFM BIW Air Leakage
Reduced Noise Transmissibility
- 26 Sones
www.autosteel.org
2004 F-150 BIW Design Targets
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Increased Use of Structural Adhesive
- 10% increase in initial Body Stiffness
- < 15% Drop in Stiffness for 10 Yrs/150K
- C/O BIW Weld Count
- Improved NVH/S&R
BIC Safety
- 5 Star NCAP – 35 MPH Rigid Barrier
- Good Rating IIHS 40 MPH Offset Crash
with Deformable Barrier
www.autosteel.org
2004 F-150 BIW Design Targets
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FMVSS Compliance
- FMVSS 216 Roof Crush
- FMVSS 207/210 Seat Pull
- FMVSS 225
www.autosteel.org
2004 F-150 Underbody
F -1 5 0 C A B U N D E R B O D Y
A ll c irc le d p a rts a re H S L A G ra d e 3 5 0
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2004 F-150 Front End
F -1 5 0 F R O N T E N D
6 1 1 1 -T 4 (A lu m in u m H o o d )
B H 2 1 0 (F e n d e r O u te r)
HSLA G R 350
(I/P A tta c h m e n t)
H SLA G R
3 5 0 (C o w l
T o p O u te r)
L a m in a te d s te e l
(D a s h P a n e l)
H S L A G R 3 5 0 (I/P
A tta c h m e n t)
M a g n e s iu m (R a d ia to r
S u p p o rt)
www.autosteel.org
2004 F-150 Body Sides
F -1 5 0 B O D Y S H E L L
D R 2 1 0 (B a c k p a n e l)
B H 2 8 0 (R o o f ra ils )
D R 2 1 0 (R o o f b o w s )
H SLA G R 350
(H e a d e r)
D R 2 1 0 (A -p illa r)
D R 2 1 0 (C -p illa r)
D O M EX 100
(R e s tra in t to w e r)
D R 2 1 0 (C -p illa r)
H SLA G R 350
(H in g e a tta c h m e n ts )
TW B: See
s lid e
TW B: Upper – H SLA
G R 3 5 0 , L o w e r – M ild
(B -p lr)
www.autosteel.org
HSLA G R 350
(B a c k p a n e l re in f)
2004 F-150 Pick up Box
F - 1 5 0 P IC K -U P B O X
D R 2 1 0 (O u te r p a n e l)
B H 2 8 0 ( F lo o r p a n )
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2004 F-150 Critical Sections
Rocker Section
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2004 F-150 Critical Sections
A Pillar Section
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2004 F-150 Critical Sections
Roof Rail Section
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2004 F-150 Laser Welded Blank
Design Drivers
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Investment
Variable Cost
Door Drop Off & Sag
Door Deflection
Roof Crush
Global Torsion
Global Bending
Offset Crash
Blank Optimization
Aesthetics
www.autosteel.org
2004 F-150 Laser Welded Blank
DOP Finished Panel
www.autosteel.org
2004 F-150 Laser Welded Blank
2003 F150 Front Hinge Reinforcement
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2004 F-150 Laser Welded Blank
2003 F150 Rear Hinge Reinforcement
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2004 F-150 Laser Welded Blank
DOP Hinge Pillar Section
www.autosteel.org
2004 F-150 Laser Welded Blank
Blank Design
www.autosteel.org
2004 F-150 Laser Welded Blank
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Advantages:
$50 Mil Tooling Save
Assembly Simplification. Less
Welding/Automation Required in Bodyshop
Part Die Elimination. 20 end item stampings
and 88 dies eliminated.
Gage Flexibility. Upgage or Downgage for
Performance Instead of Adding Parts (I.E.
Bending/Torsion, Roof Crush, Offset
Crash)
www.autosteel.org
2004 F-150 Laser Welded Blank
Disadvantages:
• Piece Cost. More Expensive Than
Traditional Construction Due to Laser
Welding and Requirement to Hide Weld
Line on Class 1
• Styling Concessions. Had to Shingle Box
Over Cab to Hide Rear Weld Line.
www.autosteel.org
The Quiet Steel®
“Quiet Steel®…was Tuned specifically to the dynamic requirements of the 2004 F-150”
¾ Frequency
¾ Temperature
¾ Stiffness
¾ Operating Environment
• Quiet Steel® reduced system cost and improved interior noise levels.
Various coatings available
(e.g. EG, pre-paint, phosphate, etc.)
Engineered
Viscoelastic
Layer
Not to scale
Dash
Oil Pan
0.6mm C Rolled
Steel
0.6mm C Rolled
Steel
Quiet Steel ®
www.autosteel.org
Damping Curve
2004 F-150 Structural Adhesive
Underbody
www.autosteel.org
2004 F-150 Structural Adhesive
Front Structure
www.autosteel.org
2004 F-150 Structural Adhesive
Body Side
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2004 F-150 Structural Adhesive
Back Panel
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2004 F-150 Structural Adhesive
Roof Panel
www.autosteel.org
2004 F-150 Crash
Stronger, High Strength Steel
Door Opening Panel (DOP)
Stronger, High Strength
Steel Rocker and Side Sill
New, High Strength Steel
Added Structure
www.autosteel.org
2004 F-150 Crash
Stronger, High Strength
Steel Torque Boxes
New, High Strength Steel
Longitudinal Members
Stronger, High Strength
Steel Cross Members
www.autosteel.org
2004 F-150 Comparison to 2003 F150
Static Stiffness:
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Global Bending (S/C)
- 2003 F-150 4150 N/mm
- 2004 F-150 8639 N/mm
Global Torsion (S/C)
- 2003 F-150 626 KNmm/Rad
- 2004 F-150 1376 KNmm/Rad
www.autosteel.org
2004 F-150 Comparison to 2003 F-150
BIW Air Leakage:
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BIC Body Air Leakage
- 2004 F-150 BIW Target 58 CFM
- 2004 F-150 BIW Actual 35 CFM
- 2003 F-150 Full Vehicle 300 CFM
- 2004 F-150 Full Vehicle 130 CFM
www.autosteel.org
2004 F-150 Comparison to 2003 F-150
BIC NVH:
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BIC Noise Transmissibility
- 2004 F-150 26 Sones
- 2003 F-150 35 Sones
High Mileage Stiffness Fall-Off
- 2004 F-150 10%
- 2003 F-150 50%
- 2004 F-150 1400 Inches of Adhesive
- 2003 F-150 189 Inches of Adhesive
www.autosteel.org
2004 F-150 Comparison to 2003 F-150
Safety:
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NCAP 35 MPH Frontal Crash
- 2004 F-150 performed very well.
NHSTA rating due out shortly
- 2003 F-150 4 Star/5 Star
40 MPH IIHS Offset Crash
- 2004 F-150 Good Rating/Best Pick
- 2003 F-150 Poor Rating
www.autosteel.org
2004 F-150 Performance
Poor
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Intrusion (mm
Marginal
350
Acceptable
300
Good
Test Data
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200
Dotted lines
show limits for:
90% Conf.
Marginal
90% Conf.
Accept.
90% Conf. Good
150
100
50
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Brake
Pedal
Footrest
Left
Toepan
Center
Toepan
Right
Toepan
Left IP
Right IP
www.autosteel.org
Door
2004 F-150
Summary:
• 2004 F-150 has made intensive use of
high strength steels throughout the BIW.
• High strength steel was a major enabler
in helping 2004 F-150 meet program
safety and attribute objectives.
• High strength steel was a major enabler
in minimizing weight and investment on
the 2004 F-150.
www.autosteel.org