Benchmarking, Proving the Concept, Design Concept

To provide the ultimate benchmark, GE Advanced Materials, Carlisle Engineered Products and Vari-Form undertook the development of the HydroPlast Structure FEM that met the OEM's performance criteria. An existing sport utility vehicle (SUV) was used, which utilizes an all-metal front end that would yield the most comprehensive data to validate the HydroPlast Structure on a vehicle.

The starting point of the validation program was to benchmark the front end of the SUV into its component parts, to understand its structure in relation to its performance requirements. Next, a design was created and a tool built for the complete HydroPlast Structure injection molded part. The design integrates the radiator, bonnet (hood) latch, washer bottle, headlamps, grille and fascia, while managing both vehicle level input and local mechanical loads. A hydroformed insert combined with NORYL GTX® resin, a modified high-performance PPO/PA alloy, are the materials of choice for HydroPlast™ Structures.

Calibrated load tests were conducted on the HydroPlast Structure front end and on the original SUV with its all-metal front end. All tests conformed to industry norms and the OEM's criteria. Criteria included mounting and torsional regularity, fixed first frequency, hood slam strength and durability, and hood latch retention.

Based in Warren, Michigan, USA, Vari-Form is part of TI automotive limited, a privately held U.K. registered company. Since 1984, Vari-Form has produced hydroformed components for OEM's around the world. Recognized as an innovator in the industry, Vari-Form's patented Pressure Sequence Hydroforming (PSH) and hole piercing technologies have greatly expanded hydroforming design parameters, and has resulted in substantial cost savings for manufacturers. (www.vari form.com).

HydroPlast and SmartLok are trademarks of General Electric Company, Carlisle Engineered Products Inc. and Vari-Form Inc.
NORYL GTX is a registered trademark of General Electric Company.

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