American automaker福特Motor Companyhas revealed the use of 3D printing in generating the high performance of its new vehicle, the 2020 Mustang Shelby GT500.
通过使用加法制造原型工具进行的超级计算机中的500多种设计的虚拟测试，福特设计师和工程师团队着手制作“有史以来最先进的性能街头法律野马”。3D原型制度位于其高级制造中心in Redford, Michigan, where the company also 3D printed the parts for the GT500. The vehicle will be released in fall 2019.
“We created and studied designs among the engineering teams and proved out different strategies long before we built our first prototype cars,” explained Matt Titus, Ford Performance vehicle engineer.
“这不仅提高了设计的有效性，而且还大大减少了开发GT500的时间以及与之相关的成本。”
Innovative 3D design for maximum performance
As well as its Advanced Manufacturing Center, the team at Ford also utilized the福特性能北卡罗来纳州康科德市的技术中心分析野马谢尔比GT500的3D冷却和空气动力学的设计。大量的设计使团队得以达到下限，制动和冷却目标，并最大程度地提高车辆的航空性能。潜力最大的设计是在几天之内打印的3D，与传统制造工艺相比，加速了开发时间。例如，3D团队对前分离器柳条的10种设计进行了打印和测试，并同时对其进行了测试以进行轨道变化，从而提高了设计测试过程的效率。
设计的物理验证是在密歇根州的福特风隧道和康科德的挡风玻璃风洞中进行的。对GT500进行了进一步的测试Virginia International Raceway,NOLA Motorsports ParkandGingerMan Raceway完善空气动力学设计并实现生产野马的创纪录时间。
野马快速轨道性能的关键是使用3D气流建模开发的精制前冷却系统，从而使GT500使用93-辛烷值的燃料可以传递700马力。该团队能够最大程度地进行整体冷却，以提取多达230千瓦的热能，而汽车可以在开阔的油门上产生，这足以加热12个房屋。
Furthermore, with the advanced simulations and prototyping process that utilized 3D printing, the team were able to manufacture a new rear spoiler design that works to deliver 379 pounds of rear downforce at 180 mph.
“This all-new aero design merges state-of-the-art design and materials technology with the craftsmanship of Ford racing expertise to create the most aero-capable Mustang ever,” said Steve Thompson, Ford Performance vehicle dynamics engineer. “It’s powerful, balanced and consistent – even over extended track runs – which works to deliver more fun and greater confidence for drivers.”
3D printing at Ford
Since revealing the use of 3D printing at its Advanced Manufacturing Center for the new Mustang, the company has made further developments in 3D printing for the manufacturing of its vehicles.
福特has also collaborated withCarbon, the Silicon Valley-based company behindDigital Light Synthesis（DLS）3D打印技术，到3D打印零件用于车辆生产。两家公司在北美国际车展（NAIAS）在底特律，其中包括Electric Parking Brake Bracketsfor the Ford Mustang GT500.
Furthermore, Ford Performance, a division of the motor company dedicated to high performance vehicles, has additively manufactured what its claims is “the largest 3D metal-printed part for a working vehicle in automotive history.” Developed at Ford’s German 3D printing lab on aConcept Laser X LINE 2000RfromGE Additive, the铝歧管入口一部分花了五天才完成。
Ellen C. Lee Ph.D., Technical Leader of Additive Manufacturing Research at the Ford Motor Company, has emphasised the compatibility of增材制造技术in the automotive industry:
“ AM在汽车中有大量应用程序，大多数AM技术都有一个解决每个用例的地方。对于系列生产零件，提供高通量的开放材料平台的技术最适合。”
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Featured image shows top down view of three variant colors of the new Ford Mustang GT500. Photo via Ford.
