Design And Development Of A High Pressure Die 'FEC' (Front End Carrier) For Exterior Automotive Applications

摘要

Traditionally vehicle body structure front end modules have been either fabricated pressed steel assemblies, fabricated pressed aluminium assemblies or plastic/steel hybrids. Magnesium die cast technical solutions are now in series production which are either welded at the "BIW" stage or bolted in the body at the exterior trim stages of production.rnMagnesium has been chosen as the preferred solution over alternative technologies such as steel or aluminium fabrications and plastic/steel hybrids because of weight saving, integration opportunities (reduced complexity/costs), superior structural performance (contribution to BIW performance) and geometric stability (fit and finish) advantages.rnThe latest "second generation design" of bolt in front end carriers (FEC's) also take advantage of further integration opportunities which have not been implemented to this extent before.rnThe single piece casting technique has shown many advantages in the location of major visual components in the front of the vehicle i.e. headlamps, grille, and bumper trim cover and thus relationship/gaps between them via 4 way and 2 way location features. An FEC acts as a "backbone" for these and other parts and eliminates tolerance stacks associated with fabricated steel/aluminium assemblies. This advantage has become an increasing priority of recent times because of the customer perception of craftsmanship. This paper discusses the design and development of the front end components to meet structural, corrosion and visual requirements.