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Ford's Innovative Computer Modeling System Saves Money, Boosts Quality


August 2006
 Filed under: FORD Car News | FORD Headlines

Ford's powertrain operations are saving time and money through industry-first software for designing cast components.

Kay Lowry , FCN (August 24, 2006) -- Virtual Aluminum Castings (VAC) software, developed by Ford, can pinpoint potential stress points in parts for engine blocks and cylinder heads while they are still on the drawing board, eliminating the need for imprecise, costly and time consuming trial and error testing.
VAC computer modeling helped create the new 3.5-liter V-6 engine's cylinder head, which will power the new Ford Edge.

"The use of VAC enabled a flawless launch, and reduced our development time by four months," said Steve Matera, systems supervisor for the engine.

To the unacquainted, the process of casting engine parts might seem like a relatively straightforward procedure: design a mold, fill it with hot liquid metal, let it cool and you're good to go. Not even close. It's a highly complex undertaking that involves design, advanced metallurgy and thermodynamics.

Minute structural changes during heat treatment, for example, may impact a part's strength. VAC can model the effect of miniscule changes in the chemical composition of an alloy, or slight thickness variations in a component well before a prototype is made.

"VAC is revolutionizing the way Ford develops cast aluminum components," said John Allison, senior technical leader at Ford Research and Advanced Engineering. "We now have the capability to ensure the feasibility of a given design without actually casting a part." The result is increased quality and significantly lowered costs, Allison added.

The VAC technology has been used during the development of more than 10 engine programs with an estimated cost savings of more than $90 million.

Growing demand for better fuel economy and reduced emissions is accelerating the need for lightweight materials such as aluminum, magnesium and their alloys. With development, the VAC approach can be adapted for areas beyond powertrain, including sheet metal body components.

Several research groups within Ford collaborated on the technology, which won a Henry Ford Technical award two years ago.

"VAC is a major accomplishment which demonstrates how Research and Development can work collaboratively within the Ford technical community," said Dr. Charles Wu, director of Manufacturing and Vehicle Design Research and Advanced Engineering. "It is user friendly software that has been transferred to computer-aided engineering groups worldwide."


Source: Ford Motor Company

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