Magna International and the Ford Motor Company are developing auxiliary frames made of a composite of carbon fiber. Design is 34 percent lighter than comparable parts of stamped steel and reduces the number of parts by 87 percent.
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| The auxiliary frame of carbon fiber originates from a joint research and development project of Magna and Ford |
According to Magna, the auxiliary frame of carbon fiber was developed
in a joint research and development project of Magna and Ford, which
examines the possible advantages and technical challenges of carbon
fiber reinforced composite materials in the chassis as well as the
resulting weight reduction. Employees of the product groups Body & Chassis as well as
Exteriors in the engineering team of Magna could significantly reduce
the weight through composites and suitable production processes, it
says. As Magna continues to report, compared to a corresponding piece of
stamped steel, it is 34 percent less weight. In addition, 45 steel parts were replaced by two injection moldings
and four metal parts, so that the number of parts processed in the
subframe fell by as much as 87 percent.
The injection molded parts are joined by adhesives and structural
rivets. The design corresponds to all performance requirements based on CAE
analyzes (computer-aided engineering), one hears. According to Magna, they are now producing prototypes of the
auxiliary frame, which then undergo component tests as well as tests
on vehicles at Ford. In the test phase, the behavior in corrosion and stone impact as
well as the screw relaxation are examined - aspects, which are
currently not covered by CAE, according to Magna
experts. Based on the experience gathered by the project team during the
production and subsequent tests of the prototype, it will also
provide a recommended design, manufacturing and assembly
process.
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