| |
 | |
Corus in action The case studies in this section illustrate how Corus combines its materials knowledge, automotive-engineering expertise and manufacturing innovation to offer its customers unique solutions to their specific needs. Expertise optimises con-rod manufacture Carmakers are increasingly turning to companies like Corus to develop innovative solutions that help designers to reduce component weight, improve service life and cut manufacturing costs  Smethwick Drop Forge (SDF), the UK’s leading forger of connecting rods for passenger and commercial vehicles, approached Corus for help in developing its con-rods. The company needed to satisfy the ongoing demand from customers for lighter-weight components, improved fatigue performance and reduced machining – taking costs out of the manufacturing process on current production components. Corus has extensive expertise in computer modelling techniques and in-depth knowledge of the application of different steel grades, which it used to reduce the weight of SDF’s con-rods by up to 15 per cent. This lighter component design in turn improves engine efficiency and contributes towards meeting stringent environmental legislation. The improved machining responses were delivered without sacrificing the strength or durability of the part. Commenting on the collaboration, Mark Adams, Managing Director SDF, said: “By partnering with Corus and utilising their material knowledge and expertise in computer simulation techniques, we have been able to carry out many iterations in a short space of time to determine optimum con-rod design for our customers.” Consistent delivery of high-quality material and service Corus materials and vehicle engineering expertise have helped to deliver weight and cost benefits to UK-based manufacturer LDV.  LDV approached Corus to undertake a number of studies to help identify weight-reduction and vehicle-assembly improvements prior to the launch of its new MAXUS range of light commercial vehicles. Corus was able to offer the support of its Automotive Engineering Group, based in Coventry, which specialises in developing innovative vehicle-engineering solutions using the latest thinking in materials and manufacturing technologies. Corus carried out gauge optimisation studies to help identify weight-saving opportunities, while maintaining the vehicle’s body stiffness and performance characteristics. The studies resulted in a 15kg per vehicle weight saving, without detriment to the robust body and chassis structural targets for MAXUS. This was no easy task, as MAXUS is 20 per cent stiffer than the company’s existing range. Clearly, the ideal time to employ this unique approach is before vehicle launch, so that savings can be introduced before capital expenditure for production tooling has begun. Collaboration cuts cost and weight 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. Tubular hydroform components for Discovery 3 Precision tubes are delivering cost-effective hydroformed components that improve strength and stiffness while reducing weight.  The Corus precision tubes facility in Zwijndrecht, the Netherlands, is supplying high-quality tubes to specialist German hydroformer Finow Automotive Eberswaldle, based in Berlin. Finow Automotive in turn supplies hydroformed components to Chassis Systems Ltd (CSL), based in Telford, UK, the joint-venture business created by DANA and GKN to produce the chassis for Land Rover’s highly acclaimed Discovery 3. The demand for lighter components remains a primary driver in the automotive industry. Tube hydroforming is one of the new enabling technologies that has the capacity to deliver cost-effective mass-produced solutions and is increasingly being used by vehicle manufacturers. Hydroforming can be used by automotive engineers to optimise future car designs with fewer components, helping to increase the strength and stiffness of critical parts, while contributing to reduced vehicle weight and therefore lower fuel consumption and CO2 emissions. The Corus Tubes Automotive and Engineering business has achieved registration to the new ISO/TS 16949:2002 quality-approval standard. Until recently, car manufacturers had focused on their own quality standards. TS 16949:2002 is a breakthrough because it represents a consensus among most of the world’s largest carmakers and is a starting point in the harmonisation and globalisation of designer-specified standards. Aimed primarily at Tier One suppliers, TS 16949:2002 is a technical specification developed and supported by vehicle manufacturers in Europe, America and Japan. It will help to define quality system requirements for the global automotive supply chain. Clean steels for critical engine components High-quality camshaft blanks from Corus save time and boost productivity for Volvo Trucks. Corus has a contract to supply Volvo Trucks with precision-machined camshaft blanks for use in the manufacture of critical engine components. Corus supplies the camshaft blanks directly to Volvo Trucks’ manufacturing facility in Skovde, Sweden. The blanks, which have been faced and centred, can be placed directly onto Volvo’s CNC machining cell, which produces the final cam profile. This saves a considerable amount of time in setting up and processing the camshafts. Lars Andersson, Corus product manager, said: “This contract demonstrates Corus’s commitment to helping the supply chain enhance productivity and improve component performance.”  Gearing up for spring market Corus has developed a grade of wire rod suitable for manufacturing the most demanding and quality-critical automotive springs.  Valve springs are in constant motion when in use, making them one of the most demanding applications for any steel. Valve-spring steel must be super-clean and meet very strict quality criteria. Experience in making other super-clean steels for automotive applications has enabled Corus to meet the significant challenge of manufacturing this premium grade. Manufacturing valve-spring steel requires low levels of non-metallic inclusions in the surface layers of the steel and tight control over other metallurgical parameters, such as surface cracks and decarburisation. A lengthy development process at Corus, employing carefully controlled casting and rolling techniques, has resulted in the successful production of an automotive spring-grade steel. This steel is now undergoing rigorous fatigue tests for valve-spring applications. As these trials continue, Corus is in a position to supply material for other critical automotive spring applications, such as clutch, suspension and transmission springs. | |
|
