Model-Based-Development of Advanced Precision Mazda Casting to Realize Celebrate Driving

Abstract

In order to realize the brand essence "Celebrate Driving", we are engaged in "Weight Reduction" as a critical theme in cylinder head casting area. However, if we easily pursue to reduce thickness for the weight reduction, the limit of the product function will be reached. Thus, the verification technology of function limit at each part with high accuracy is necessary. For that, we assumed that, in addition to several stresses which occur in driving, the residual stress distribution which remains in the product at manufacturing is the crucial factor. So, we developed the residual stress verification technology and structured the product development process that the residual stress distribution is coupled to the function verification at R&D Division.

This time, the cylinder head of All-New Mazda3 has been model-base-developed by this technology and we realized to reduce thickness and weight as the industry top level while keeping product functions. This article introduces the approach of the technology.