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Metal Thinning Analyses Supplement Circle Grids

Budd Co.-Stuart P. Keeler, Ernie R. Eisenbach
  • Technical Paper
  • 1997-20-0054
Published 1997-09-30 by Automotive Technology Group, Inc. in United States
Circle grid analysis and forming limit diagrams are utilized today in many press shops throughout the world. Common uses include die tryout, material evaluation, lubricant assessment, process monitoring, troubleshooting, safety margin improvement, and a wide variety of other applications described in the literature. However, circle grid procedures have certain restrictions which tend to inhibit wider press shop implementation. Metal thinning analyses using an ultrasonic sheet thickness gage for determining the stamping thickness strain overcome many of the circle grid restrictions. Today, metal thinning analyses supplement circle grid analyses to rapidly provide key stamping information. Press shop applications and specific case histories are described.

Finite Element Analysis Structural Optimization Using Statistical Engineering Techniques

Budd Co.-Frederick A. Shahly
  • Technical Paper
  • 1997-20-0001
Published 1997-09-30 by Automotive Technology Group, Inc. in United States
The automotive industry is continually striving to minimize part cost and weight. Finite element analysis (FEA) is a cost-effective way of optimizing part design, and thus minimizing part cost and weight. The Budd Company has developed a finite element analysis structural optimization method using statistical engineering design-of-experiment techniques. The method cannot only take into consideration structural optimization, but can also factor in cost and weight. The steps taken in the technique are detailed. Also, an example is shown to explain the procedure further.

Smc-Integrated, Front-End System Used on 1996 Ford Taurus and Mercury Sable

Budd Co.-Mohammed Mahmood
  • Technical Paper
  • 1997-20-0041
Published 1997-09-30 by Automotive Technology Group, Inc. in United States
The 1996 Ford Taurus and Mercury Sable employed a unique front-end system design which featured a two-piece SMC upper and lower radiator support or integrated front-end system (IFES). The IFES is an enabling technology that aided overall quality, customer satisfaction, performance, improved ride and handling, as well as adding to the front-end styling appearance.This concept had its roots in a previously proposed one-piece design which was to accommodate a time-proved and dimensionally stable assembly methodology. A team of Ford Motor Company engineers was formed consisting of specialists from manufacturing, assembly, finance, vehicle development, planning, materials and systems design. A significant breakthrough occurred as a result of the recognition of benefits provided through parts consolidation, ease of assembly and modular design.The Budd Company, Plastics Division was responsible for materials development, tooling and manufacturing process; and was a co-located partner during the system design and verification process. This close partnership between Ford Motor Company and The Budd Company enabled a smooth transition from initial engineering concept and prototypes, to final vehicle launch and production.This paper addresses theā€¦

An Overview of the Development Program for Hi-Flex Smc Fenders for the 1995 1/4 Continental

Budd Co.-Terry Ingham
Ford Motor Co.-Iskander Farooq, Debra Keller, Frank Migda, Gary Rocheleau, Rick Wykoff
  • Technical Paper
  • 1994-20-0005
Published 1994-09-26 by Automotive Technology Group, Inc. in United States
This paper will discuss the development process used to implement Budd Company's Hi-Flex SMC into a fender application for use on the 1995 1/4 Continental (FN74). In this application, the plastic fender offers a weight and cost savings when compared to a steel fender. The Hi-Flex SMC is also stone chip, dent and ding and corrosion resistant. The development of this project involved a team with members from Budd Company, paint and adhesive suppliers, and many divisions within Ford. Experiments were run on raw materials at Budd, on surrogate parts at BASF, and on prototype parts at the Wixom pilot paint facility. A pilot program of 80 Continentals (rental units) was run at Wixom Assembly Plant in the spring of 1993. The results of these studies were the release of a new worldwide material specification and the release of a Hi-Flex SMC fender for use on the 1995 1/4 Continental
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A Comparison of Aluminum, Sheet Molding Compound and Steel for Hoods

Budd Co.-Stephen E. Rawe
Chrysler Corp.-Dominic J. Constantini
Published 1992-02-01 by SAE International in United States
A unique opportunity arose to make a direct comparison of aluminum, sheet molding compound (SMC) and steel using a common hood design. In considering all possible material combinations of inner and outer panels, it was discovered that some of the combinations were incompatible due to material properties. Only the compatible material combinations were considered. Three different joining techniques - welding, bonding and bonded hem flanging - were evaluated. The cost, weight and structural performance of the chosen hood material combinations were established. Areas of further development were identified, including design optimization for specific material combinations.
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Status of the Development of Improved Vehicle Side Structures for the Upgrade of Fmvss 214

Budd Co.-Michael Pavlick
National Highway Traffic Safety Administration-William Thomas Hollowell
  • Technical Paper
  • 806051
Published 1980-01-01 by National Highway Traffic Safety Administration in United States
In its 1977 rulemaking plan, the National Highway Traffic Safety Administration established the upgrade of side impact protection as a top priority. This paper reports the progress to date on the developments to upgrade the design of vehicle side structures. Also presented is the philosophy used for these upgrades. Finally, the plan for integrating the upgraded vehicles into the other support areas for this rulemaking activity is discussed.
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The Development of the Modern Truck Disc Wheel

Budd Co.-J. N. Bradley
Published 1970-02-01 by SAE International in United States
The development of the truck disc wheel from World War II through the present period is traced. Both the tubed and tubeless developments are discussed with a look at where we are today, and what some of the wheels will be in the immediate future.The duo rim is discussed in some detail as the answer to a requirement for an orderly development from tubed to tubeless.
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An Old Material Meets a New Challenge - Integral Cast Iron Hub and Disc Development

Budd Co.-Gerald L. Goldberg, Trevor N. James
Published 1969-02-01 by SAE International in United States
Cast iron has been used as an engineering material for 2000 years. The concept of an integral hub is not new to the automotive engineer since it dates back at least 40 years. For economic considerations, the use of cast iron has been merged with the concept of an integral hub and disc for passenger car usage. This paper discusses the various problems involved in the utilization of cast iron and includes details of various tests and their results necessary to prove out this design.
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Passenger-Car Bodies-Their Design and Development

Budd Co.-A.R. Lindsay
Published 1952-01-01 by SAE International in United States
THE main steps to be taken in the design and development of an automobile body are outlined here.First, the art department, given the principal dimensions, produces several design studies for further consideration. Next after the necessary modifications are made, scale models are formed of wood and clay.Later, a full-size clay model is built up, from which full-size layouts can be drawn. Next, a full-size mockup is made, from which full-size drafts are made on aluminum sheets painted white.The lines on these drafts are used to make templates, from which mahogany die models are made of each part of the body. These models are then used in cutting the dies.
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