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 Pre-production studies by Corus enabled Ford to reduce the costs of manufacturing its new Ford Galaxy – at the same time as reducing the vehicle’s weight. With the growing use of high-tech steels in today’s automotive press shops, it is increasingly important for carmakers to fully understand how a material will deform and flow during the pressing process, in order to ensure capability, quality and performance in the finished component. Working closely with Ford engineers at Merkenich, Germany, a collaborative project was undertaken by Corus on the new Ford Galaxy. This included feasibility, parts-integration and cost and weight reduction studies on the rear floor, rear cross member and heel kick panels. The study on the rear-floor panel looked at opportunities to reduce the gauge, and therefore the weight of the panel, while ensuring that the complex panel shape was feasible to press. A detailed parts-integration study of the rear-floor panel showed that it was possible to use just one part instead of the originally planned two, allowing Ford to save on tooling, process and manufacturing costs. By utilising the superior properties of dual-phase steel, it was also possible to down-gauge the heel board and rear cross members from the traditionally specified High Strength Low Alloy (HSLA) grades, while retaining the same side-impact performance. | |
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