Practical Application of Computer Modeling for Solutions to
Premature Tooling Failure for
Large Structural Components G. Guilliams Hayes Lemmerz Int., Inc., Ferndale, MI, USA Traditional computer engineering applications are typically utilized during the pre-launch, engineering intensive phases of program/product development. Applications such as FEA, mold flow, and solidification are traditionally pivotal in early decisions with respect to product design and manufacturability. However, primarily, these capabilities are housed at developmental engineering facilities where the "next" programs are typically cued up and started the instant the product is handed off to the manufacturing facility. Thus, these applications are rarely available to assist the production facility in their focus to constantly reduce cost and drive continual improvement. Hayes Lemmerz Int., Inc. launched a greenfield VRC/PRC foundry in Montague, Michigan in 2002 for the production of suspension components. Primary products launched include two front knuckle programs, two front lower control arms, and an industry significant, single piece cast #2 crossmember. The front lower control arms and #2 crossmember are for the Ford FN145 program, better known as the Lincoln Town Car, the Mercury Grand Marquis, and Ford Crown Victoria. Shortly into production, severe, even catastrophic failure, in the form of cracks in the #2 crossmember tooling became a critical focus for the production team. This presentation will explain the steps taken, cooperatively, between the production facility and the technical resource center, to utilize CAE, CAD, moldflow, and solidification modeling to first verify the field failures with real process measurement, and reverse engineer a solution for the elimination of these severe cracks to achieve an acceptable tool life. |