- Collaborative R&D project with Ford Motor Company
- Concept design yields 34 percent mass reduction; 87 percent
reduction in number of parts
- Prototypes now undergoing vehicle-level testing
SAILAUF, Germany, March 14, 2017 /CNW/ - In pursuit of lower
vehicle weight to reduce emissions and improve fuel efficiency,
Magna International Inc., in cooperation with Ford Motor Company,
developed a prototype carbon fiber composite subframe which reduces
mass by 34 percent compared to making a stamped steel
equivalent.
By replacing 45 steel parts with two molded and four metallic
parts, the prototype subframe achieves a dramatic 87 percent
reduction in the number of parts. The moldings are joined by
adhesive bonding and structural rivets.
The carbon fiber subframe is the result of a research and
development project between Magna and Ford to investigate potential
mass-reduction benefits and technical challenges of using carbon
fiber-reinforced composites in chassis applications. The subframe
is a key part of a vehicle's structure, typically providing a place
to attach the engine and wheels while also contributing rigidity
and crash management.
"When we are able to work in close partnership with a customer
at the beginning of their design and engineering processes, it's an
opportunity to bring our full Magna capabilities to bear," said
Grahame Burrow, President of Magna
Exteriors, speaking at JEC World 2017 in Paris. "We are able to take a clean-sheet
approach with design, materials and processing, collaborate with
the customer and within our product groups, and deliver a solution
with the potential to really move the needle in terms of aggressive
lightweighting without sacrificing styling or performance."
Magna's engineering team – a collaborative effort between the
company's body & chassis and exteriors product groups –
combined its unique, full-vehicle knowledge on the design,
materials and processing to address the challenge of reducing
weight using composite materials and manufacturing processes.
The design has passed all performance requirements based on
computer-aided engineering (CAE) analyses. The prototype subframes
are now being produced by Magna for component and vehicle-level
testing at Ford.
"Collaboration is the key to success in designing lightweight
components that can give our customers fuel economy improvements
without compromising ride and handling, durability or safety. We
must continue to work hard to achieve these lightweight solutions
at the most affordable costs. Magna and Ford working together on
this carbon fiber composite subframe is a great example of
collaboration on advanced materials," said Mike Whitens, Director of Vehicle Enterprise
Systems within Ford Research and Advanced Engineering.
The testing phase will evaluate corrosion, stone chipping and
bolt load retention, which aren't currently measured by CAE. The
project team will also develop a recommended design, manufacturing
and assembly process with the experience gained during the
prototype build and subsequent testing.
"We've been a pioneer in the use of lightweight materials for
many years now," added Burrow. "First we launched the CF hood for
the Cadillac CTS/ATS-V series, followed by a carbon fiber grille
opening reinforcement for the Mustang Shelby Cobra GT500. Applying
our expertise now to a structural component like the subframe is
another step forward as we continue to help our OEM partners meet
their goals."
TAGS
Automotive innovation, automotive lightweighting, structural
composite, carbon fiber, JEC World 2017
ABOUT MAGNA INTERNATIONAL
We are a leading global automotive supplier with 317 manufacturing
operations and 102 product development, engineering and sales
centres in 29 countries. We have over 155,000 employees focused on
delivering superior value to our customers through innovative
products and processes, and world class manufacturing. We have
complete vehicle engineering and contract manufacturing expertise,
as well as product capabilities which include body, chassis,
exterior, seating, powertrain, active driver assistance, vision,
closure and roof systems. We also have electronic and software
capabilities across many of these areas. Our common shares trade on
the Toronto Stock Exchange (MG) and the New York Stock Exchange
(MGA). For further information about Magna, visit our website at
www.magna.com.
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SOURCE Magna International Inc.