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Powdered Metal to Metal Stamping Conversion of an ABS Assembly for the Automotive Industry

Automatic Braking System Assembly
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Automatic Braking System Assembly
 

A major auto manufacturer asked A.J. Rose to evaluate a powdered metal, automatic braking assembly. Through collaboration and consultation, the customer and A.J. Rose experts concluded that the half shaft braking assemblies could be converted with major cost and weight savings. The redesigned stamped steel part would actually offer improved functionality, while cutting the overall weight from 1.5 lbs. to .75 lbs., and decrease the cost per unit by 40%. A.J. Rose provided the finite element analysis (FEA), manufactured the prototypes, and stamped the 1008 1010 HRPO SAE steel with a Geomet finish. We ultimately produced 1.5 million units annually, with a total savings over 40% a year.

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Powdered Metal to Metal Stamping Conversion Project Highlights

Product Name Automatic Braking System Assembly
Product Description This ABS assembly is used with a sensor application and helps monitor rotation speeds for each wheel corner.
Capabilities Applied/Processes Manufacturing Conversion Evaluation
  • Redesign of component
  • Generate CAD drawings & models
  • Finite Element Analysis (FEA)
  • Our engineers evaluated this component and determined it was possible to convert it from a powdered metal part to a stamped steel part
  • The component dropped by 40% in cost 
  • Weight of the component went from 1.5lbs down to .75lb
Prototype Manufacturing

Metal Stamping
Material Used 1008 1010 HRPO SAE Steel
Material Finish Geomet
Benefits Functionality was Improved
Reduction In warranty claims
Cost savings over 40% a year
Industry for Use Automotive
Standards Met Customer supplied specifications
Safety Braking
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