Yan Pugh-Jones Frederick Walker 1 Aston Martin DB11, GALM, Birmingham, 2017 2 DB11 – Project Mission
Architecture
Manufacturing
Summary
Aston Martin DB11, GALM, Birmingham, 2017 3 DB11 – Project Mission Second Century Plan 7 new models in 7 years
Aston Martin DB11, GALM, Birmingham, 2017 4 DB11 – Project Mission VH Platform
DB9 Vantage DBS Rapide Vanquish II
Coupe
Convertible
Special Projects
Aston Martin DB11, GALM, Birmingham, 2017 5 DB11 – Project Mission Next Generation Platform
2016
Coupe
Aston Martin DB11, GALM, Birmingham, 2017 6 DB11 – Project Mission Next Generation Platform
Aston Martin DB11, GALM, Birmingham, 2017 7 DB11 – Project Mission Brief
“The world’s most timeless and elegant sports grand tourer” • The heart of Aston Martin: The fulcrum of our sports car range
• Supreme elegance and sports car precision, agility and effortless touring
ability
• Exceptional breadth of character: GT composure allied to sports car
excitement
• Forceful performance and everyday usability Aston Martin DB11, GALM, Birmingham, 2017 8 21 months exterior design freeze to J1 18 months interior design freeze to J1
DB11 – Project Mission Usability & Package +149
+54 +95 1145 637 Legroom Couple
+65 2805 +50 4739
Aston Martin DB11, GALM, Birmingham, 2017 9 DB11 – Project Mission Usability & Package
+76l +9 260l 982 Boot volume Headroom
-3 1279
+38 DB9 Passenger Seat Isofix 2060 Only 2 Rear Seat Isofix Positions
Aston Martin DB11, GALM, Birmingham, 2017 10 DB11 – Project Mission Performance
Performance Change from DB11 DB9 V12 Displacement: 5.2l -13% Power: 600bhp +18% CdA: <0.650 -17% 0-62mph (100kph): 3.9s -15% 0-100mph <8.0s -16% Vmax: >200mph +10% CO2g/(km * bhp): <0.5g -26%
Aston Martin DB11, GALM, Birmingham, 2017 11 DB11 – Project Mission Exterior Design
• Floating Arc cantrail • Large highly sculpted front hinging aluminium clamshell • Iconic and authentic Aston Martin Grille • LED headlamps
Aston Martin DB11, GALM, Birmingham, 2017 12 DB11 – Project Mission Interior Design
• All new electrical architecture • Electrically operated centre console • First time application of knee airbag for Aston Martin Aston Martin DB11, GALM, Birmingham, 2017 13
DB11 – Project Mission
Architecture
Manufacturing
Summary
Aston Martin DB11, GALM, Birmingham, 2017 14 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 15 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 16 Architecture Material Mix – Underframe
DB9 • Aluminium Extrusion intensive whilst also utilising gravity die Castings and both simple and superplastically formed 5XXX Series Sheet 0% 0%
Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles
Aston Martin DB11, GALM, Birmingham, 2017 17 Architecture Material Mix – Underframe
DB11 Platform • Over twice the amount of aluminium sheet metal used compared to DB9 • 6XXX series sheet for increased strength over 5XXX series
• Integration of a one piece structural bodyside 18% 6% 41% 35%
Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles
DB11 Underframe
Aston Martin DB11, GALM, Birmingham, 2017 18 Architecture Material Mix – Underframe
• Aluminium Sheet metal used in areas for package efficiency, organic development through CAE, robust body sealing and dimensional accuracy
18% 6% 41%
35%
Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles
Aston Martin DB11, GALM, Birmingham, 2017 19 Architecture Material Mix – Underframe
• Aluminium gravity die castings for integration and complex nodal joints
18%
6% 41% 35%
Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles
Aston Martin DB11, GALM, Birmingham, 2017 20 Architecture Material Mix – Underframe
• Aluminium extrusion profiles for crash load paths and reinforcements
18% 6% 41% 35%
Material Mix by Mass Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Aluminium Die Castings Aluminium Extrusion Profiles
Aston Martin DB11, GALM, Birmingham, 2017 21 Architecture Material Mix – Body + Closures
11%
42%
38% 4% 5%
DB11 Body & Closures Material Mix (ExcludingAluminium Die Underframe) Castings Aluminium Sheet 5XXX Series Aluminium Sheet 6XXX Series Mild Steel Sheet Sheet Moulding Compound (SMC)
Aston Martin DB11, GALM, Birmingham, 2017 22 Architecture Material Mix – Body + Closures
Closures Skins
Front End Module Bridging Structure
Aston Martin DB11, GALM, Birmingham, 2017 23 Architecture Mass Reduction
Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg +14kg
40kg -15kg
-8kg
268kg 247kg DB9 DB9 BIW DB11
Aston Martin DB11, GALM, Birmingham, 2017 24 Architecture Mass Reduction
Structural Style + Requirements Package +5kg
19kg +14kg
268kg DB9 DB9 BIW
Aston Martin DB11, GALM, Birmingham, 2017 25 Architecture Mass Reduction
Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg
40kg -15kg
-8kg
268kg 247kg DB9 DB11DB9 BIW BIW DB11
Aston Martin DB11, GALM, Birmingham, 2017 26 Architecture Mass Reduction
Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg
40kg -15kg
-8kg
268kg 247kg DB9 DB11 BIW DB11
Aston Martin DB11, GALM, Birmingham, 2017 27 Architecture Mass Reduction – Optimisation
Topology Optimisation Design Space Creation
Aston Martin DB11, GALM, Birmingham, 2017 28 Architecture Mass Reduction – Optimisation
Topology Optimisation
• Topological optimisation to minimize mass using derived stiffness targets for multiple loadcases
Aston Martin DB11, GALM, Birmingham, 2017 29 Architecture Mass Reduction – Optimisation
Topology Optimisation
Where material CAE CAD Initial concept to CAE CAD Final Production is wanted deliver load Form paths
Aston Martin DB11, GALM, Birmingham, 2017 30 Architecture Mass Reduction – Optimisation
Casting Shape Optimisation
Design Space for Casting Shape CA CAE start of shape D optimisation from optimisation CAE into CAD
Aston Martin DB11, GALM, Birmingham, 2017 31 Architecture Mass Reduction – Optimisation
Casting Shape Optimisation
Casting Final manufactured Starting model for CA manufacturing CA form w/ optimised CAE CAE CAE D simulation D mechanical properties development sympathetic to stress and wall thickness map for wall thickness optimisation Aston Martin DB11, GALM, Birmingham, 2017 32 Architecture Mass Reduction – Optimisation
Gauge Optimisation • Completed throughout design development to inform design and understand redundant material
• First applied using global statics and dynamics…
• …then iteratively balanced with energy management requirements
• Applied with component manufacturing feasibility constraints and for commercial benefit of sheet availability
Aston Martin DB11, GALM, Birmingham, 2017 33 Architecture Mass Reduction – Optimisation
Stamping Simulation
• Finished part gauge prediction using forming simulation
• Finished Part strength and elongation mapping ! further gauge optimisation
Thinnin Effective Plastic g Strain Map
Aston Martin DB11, GALM, Birmingham, 2017 34 Architecture Mass Reduction
Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg
40kg -15kg
-8kg
268kg 247kg DB9 DB11 BIW DB11
Aston Martin DB11, GALM, Birmingham, 2017 35 Architecture Mass Reduction – Joint Design / Integration
Functional Integration – A Pillar Castings
• Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement
Aston Martin DB11, GALM, Birmingham, 2017 36 Architecture Mass Reduction – Joint Design / Integration
Functional Integration – A Pillar Castings
• Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement • IP Cross Car Beam Mountings
6 Major Vehicle Systems Mounted to 1 Node
Aston Martin DB11, GALM, Birmingham, 2017 37 Architecture Mass Reduction – Joint Design / Integration
Functional Integration – A Pillar Castings
• Door Hinges • Bonnet Latches • Door Gas Strut Body Mount • Wipers • Damper Top Longitudinal Reinforcement • IP Cross Car Beam Mountings
6 Major Vehicle Systems Mounted to 1 Node
• Node Also Forms Major Part of the Loadpaths for: - Roof Crush - Front Impact (e.g. 64ODB) - Side Impact (e.g. Fed side barrier) - Torsional & Bending Stiffness
Aston Martin DB11, GALM, Birmingham, 2017 38
Architecture Mass Reduction – Joint Design / Integration
Functional Integration – Front Damper Mounting • Sand Cored hollow die casting used to reduce part count and optimise package space to larger engine and for structural efficiency
Hollow 9 Parts Sand core into 1
DB9 DB11
Aston Martin DB11, GALM, Birmingham, 2017 39 Architecture Mass Reduction
Structural Style + Joint Design/ Optimisation Materials Requirements Package Integration +5kg -17kg 19kg +14kg
40kg -15kg
-8kg
268kg 247kg DB9 DB11 BIW DB11
Aston Martin DB11, GALM, Birmingham, 2017 40 Architecture Mass Reduction – Materials
• VH Platform used 5XXX for sheet metal 350 • 5XXX series has excellent formability but low strength in comparison to those 300 available in heat treated 6XXX series 250
• Heat Treatment required to achieve best 200 available strengths 150 Stress(MPa) 100
50
0 0 5 10 15 20 25 30 Strain (%)
6XXX Sheet
Aston Martin DB11, GALM, Birmingham, 2017 41 Architecture Mass Reduction – Materials
• High temperature oven used to cured adhesive
• DB11 exploits adhesive oven curing process to achieve in line alloy heat treatment at no extra cost
• AA6016 selected due to reduced sensitivity to natural aging in T4 condition (compared to other 6XXX) and commercial availability
• Dimensional issues of heat treatment removed by baking as a structural assembly
Stamping Conversion Adhesive Mill Assembly Paint supplier coating Oven
Natural aging
Aston Martin DB11, GALM, Birmingham, 2017 42 Architecture Mass Reduction – Materials
• Metal heat treatment limited by
adhesive cure requirements 350
• Oven temperature profile optimised for 300
both adhesive performance and sheet 250 heat treatment through simulation 200
150 Stress(MPa) 100 Over 100% Increase in 50 Air Temp strength whilst maintaining Coldest Panel Temp 0 formability! Hottest Panel Temp 0 5 10 15 20 25 30 Temperature Temperature Strain (%)
Time WARM UP COOL CURE OVEN 1 & 2 OVEN DOWN
Aston Martin DB11, GALM, Birmingham, 2017 43 Architecture Ride & Handling – Full Body Stiffness
Outstanding Body Structural Ride & Handling Targets GT ride Efficiency Targets
Projected Area (m²) Torsional Stiffness (kNm/°) Lightweight M Index = 4.60 34.0 Kt x A 24.5 4.29
M = BIW Mass DB9 DB11 DB9 DB11 Kt = Torsional Stiffness A = Track x Wheelbase 6% bigger… Wider Track, 39% stiffer… Improvements Longer Wheelbase in bending and local stiffness's combined with robust modal alignment
Aston Martin DB11, GALM, Birmingham, 2017 44 Architecture Ride & Handling – Full Body Stiffness
Outstanding Body Structural Ride & Handling Targets GT ride Efficiency Targets
Lightweight Index Projected Area (m²) Torsional Stiffness (kNm/°)
2.69 4.60 34.0 24.5 1.67 4.29
DB9 DB11 DB9 DB11 DB9 DB11 6% bigger… Wider Track, 39% stiffer… Improvements 38% improvement… Longer Wheelbase in bending and local stiffness's combined with robust modal alignment
Aston Martin DB11, GALM, Birmingham, 2017 45 Architecture Ride & Handling – Full Body Stiffness
Examples: Torsion & Bending - Notable Optimized Organic-shaped features Structure
Engine X- brace Soft mounted rear sub-frame: True GT
Tunnel brace
Sill Section: I & J values
Aston Martin DB11, GALM, Birmingham, 2017 46 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 47 Architecture Packaging – Door Aperture
DB9 DB11
+85mm +20mm
Increased use of sheet metal in DB11 versus extrusions in DB9 has allowed an overall increase in door aperture length of 105mm, significantly aiding customer ingress and egress.
Aston Martin DB11, GALM, Birmingham, 2017 48 Architecture Packaging – A-Pillar Visibility (HFQ®)
• Reducing A pillar size with increased roof crush requirements and low rake roof line
Aston Martin DB11, GALM, Birmingham, 2017 49 Architecture Packaging – A-Pillar Visibility (HFQ®)
Dimensio n High Section Optimised Modulus
Internal Radii – 1.5T
Internal Radii HFQ® Sheet in Dimension – 1.5T AA6082-T6 @ optimised 2.5mm Thickness
Aston Martin DB11, GALM, Birmingham, 2017 50 Architecture Packaging – A-Pillar Visibility (HFQ®)
Blanking Solution Heat Transfer Forming Treatment to press • Technology licensed under Impression Technologies
• Components are rapidly Temperature formed at elevated temperatures at which ductility is high (e.g. 400-500°C) ! High form Time
Aston Martin DB11, GALM, Birmingham, 2017 51 Architecture Packaging – A-Pillar Visibility (HFQ®)
In-die Blanking Solution Heat Transfer Forming Post Form Heat Treat Quenching Treatment to press • Technology licensed under Impression Technologies
• Components are rapidly Temperature formed at elevated temperatures at which ductility is high (e.g. 400-500°C) ! High form 5-20s typical Time • In-die Quenching means that 6XXX series grades leave the press in the solution heat treated condition. Components are then artificially aged to T6 strengths ! High strength
• Hot Formed Quenching™ with AA6082-T6 is typically ~20% higher yield strength than AA6016- AMH
Aston Martin DB11, GALM, Birmingham, 2017 52 Aston Martin DB11, GALM, Birmingham, 2017 53 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 54 Architecture Robust Safety
Front Impacts Side Impacts (high and low speed)
Rear Impacts (high and low speed) Other strength requirements: e.g.FMVSS210
Roof Crush Pedestrian
Aston Martin DB11, GALM, Birmingham, 2017 55 Architecture Robust Safety – Front
Demanding Style Extremely tight front package: - Large twin-turbo V12 engine - Short front overhang (reduced 16mm versus DB9)
Aston Martin DB11, GALM, Birmingham, 2017 56 Architecture Robust Safety – Front
Front Crash Concept
Aston Martin DB11, GALM, Birmingham, 2017 57 Architecture Robust Safety – Front
Front Impact 64ODB Exceeds regulatory standards: Frontal offset deformable barrier performed not at the regulatory 56kph but at EuroNCAP spec 64kph CA Tes E t
Aston Martin DB11, GALM, Birmingham, 2017 58 Architecture Robust Safety – Front
Front Impact 64ODB – Development Meticulously engineered to deliver the uncompromised style featuring a small front overhang and extremely tight powertrain package The The The challenge concept development
Enabling Secondary cans Front subframe structural Sub-assembly to crush (sequentially) fuse validation by CAE / Test correlation Aston Martin DB11, GALM, Birmingham, 2017 59 Architecture Robust Safety – Front
Front Impact 64ODB – Development Robust safety delivered: Under-view demonstrates the effective operation of the design
CA Tes E t
Aston Martin DB11, GALM, Birmingham, 2017 60 Architecture Robust Safety
Front Impacts Side Impacts (high and low speed)
Rear Impacts (high and low speed) Other strength requirements: e.g.FMVSS210
Roof Crush Pedestrian
Aston Martin DB11, GALM, Birmingham, 2017 61 Architecture Robust Safety – Side
Demanding Style Heavily sculpted side profile: - reduces visual weight of vehicle - allows for striking feature line at bottom of door.
Aston Martin DB11, GALM, Birmingham, 2017 62 Architecture Robust Safety – Side
Side Crash Concept
Aston Martin DB11, GALM, Birmingham, 2017 63 Architecture Robust Safety – Side
Side Pole Impact Side pole impact: Delivered with no compromise to the beautiful slim-waist body-style
CA Tes E t
Aston Martin DB11, GALM, Birmingham, 2017 64 Architecture Robust Safety – Side
DB9 DB11
The challenge: - Heavily sculpted side profile results in a limited section depth to sill in area overlapping cross car structure
130mm 65mm
Aston Martin DB11, GALM, Birmingham, 2017 65 Architecture Robust Safety – Side
Side Pole Impact – Development Me#culously*engineered*from*component4level*to*whole4vehicle4level!
The The The challenge concept development Tunnel-brace key-hole feature
Door-beam slots
Occupant seated between: 1. H-Frame underfloor loadpath Component level High tunnel & low tapering sill 2. Slotted door beam optimization by CAE & Test Aston Martin DB11, GALM, Birmingham, 2017 66 Architecture Robust Safety – Side
Side Pole Impact – Development CAE X-section and Crash-test on-board view demonstrate the robust performance of the underfloor load-path
CA Tes E t
Aston Martin DB11, GALM, Birmingham, 2017 67 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 68 Architecture Beautiful Styling – Clamshell Bonnet
Aston Martin DB11, GALM, Birmingham, 2017 69 Architecture Beautiful Styling – Clamshell Bonnet
1933mm
1706mm 438mm
Outer: 1.1mm AC170 Inner: 1.0mm 5182 Single Draw Tool
Aston Martin DB11, GALM, Birmingham, 2017 70 Architecture Beautiful Styling – Clamshell Bonnet
<30mm between blank and draw bead
Development Tool 24 feasibility simulations 3 draw bead recuts 40+ drawn shells
Aston Martin DB11, GALM, Birmingham, 2017 71 Architecture Beautiful Styling – Authentically Low Front End
Low bonnet line Bonnet to leading edge of vehicle despite large V12 engine
910mm
Solid aluminium grille Aggressive, forward leaning stance Aston Martin DB11, GALM, Birmingham, 2017 72 Architecture Beautiful Styling – Authentically Low Front End
Carefully placed cut outs in leading edge of Tuned sprung break outs between grille and bonnet structure and splitter to undertray
Aston Martin DB11, GALM, Birmingham, 2017 73 Architecture Beautiful Styling – Side Profile
Aston Martin DB11, GALM, Birmingham, 2017 74 Architecture Beautiful Styling – Side Profile
- AC200 aluminium using - 3 stage hydraulic cold forming process - Draw, Re-draw, Restrike
220mm
Aston Martin DB11, GALM, Birmingham, 2017 75 Architecture Architectural Goals
Highly Efficient Structure
Generous GT State of the Art Packaging Aerodynamics
Robust Safety Beautiful Styling
Aston Martin DB11, GALM, Birmingham, 2017 76 Architecture State of the Art Aerodynamics
Aeroducttm
Curlicue
Aston Martin DB11, GALM, Birmingham, 2017 77 Architecture State of the Art Aerodynamics
Aeroducttm
Aeroducttm
Curlicue
Aston Martin DB11, GALM, Birmingham, 2017 78 Architecture State of the Art Aerodynamics – Aeroduct®
Body mounted Dynamic sprung duct body to decklid interface Decklid mounted duct Deployable high speed gurney flap
Aston Martin DB11, Euro Car Body, Bad Nauheim, 2016 79 DB11 – Project Mission
Architecture
Manufacturing
Summary
Aston Martin DB11, GALM, Birmingham, 2017 80 Manufacturing Location
Engineering Design Studio Gaydon
DB11 was designed, engineered Prototype and is manufactured at our HQ in Manufacturing Workshop Gaydon - UK
Total Plant Manufacturing Area: 38,000sqm
Aston Martin DB11, GALM, Birmingham, 2017 81 Manufacturing Manufacturing Layout
Pilot Build New Body Shop for DB11 All Legacy + Future Production Models relocated – Legacy BIW Aug 2014. Production Off Tracks Paint Plant Assembly All Models
Legacy DB11 Trim & Underframe Final Assembly Production
Interior Trim Area All Models New Body Shop for DB11: 5,700sqm
Aston Martin DB11, GALM, Birmingham, 2017 82 Manufacturing Assembly Sequence - Underframe 83
Underframe
Aston Martin DB11, GALM, Birmingham, 2017 Manufacturing Assembly Sequence - Underframe
Aston Martin DB11, GALM, Birmingham, 2017 84 84 Manufacturing Assembly Sequence – No Underframe Derivatisation
DB9 DB11
RHD
RHD & LHD
LHD
Single derivative out of body shop for both hands and all world markets.
Aston Martin DB11, GALM, Birmingham, 2017 85 Manufacturing Underframe Joining Summary
113m of hot cure BETAMATETM structural adhesive
841 Structural Rivets
437 Self Pierce Rivets
52 Drill Drive Screws
Aston Martin DB11, GALM, Birmingham, 2017 86 ®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow! Architecture Joining Concept
Improved stress distribution Improved Tolerance vehicle Joint Design ability stiffness
Adhesive selection ADHESIV Maintained material Improved NVH properties E JOINING Surface pre-treatment
Increased design Improved sealing Adhesive processing flexibility Improved corrosion resistanc e JOINT PERFORMANCE
Aston Martin DB11, GALM, Birmingham, 2017 87 Architecture Joining Concept –Bill of Process to achieve Joint Perforamce
Supplied Conversion & 100% Robotic Adhesive components Corrosion Coating Application
CASTINGS
ANODISING
PANELS l ~20 V 1.4/ A/ d m 2 APPLIED AT PART LEVEL Anode l (material to be anodised) l
Cathode l Electrolyte l (sulphuric acid) EXTRUSIONS Cooling l
Aston Martin DB11, GALM, Birmingham, 2017 88 Architecture Joining Concept –Bill of Process to achieve Joint Perforamce
Create Joint Mechanical Joint Adhesive Cure Closure
Double Sided ! Part Fixture SPR Located / No Holes Required
Single Sided OVEN with matching holes ! Gun Access / Part STRUCTURA Self Location L RIVET
Single Sided with Pilot ! Gun Access / Joint DDS Size / Earth Continuity
Aston Martin DB11, GALM, Birmingham, 2017 89 Architecture Joining Concept –Bill of Process to achieve Joint Perforamce
Large Temperature Delta Adhesive Cure
Adhesive Temp Cure % 100% )
DegC OVEN Ramp Up Cure%
Temp ( Temp Adhesive not cured. Parts free to expand.
Time (Mins)
Aston Martin DB11, GALM, Birmingham, 2017 90 Architecture Joining Concept –Bill of Process to achieve Joint Perforamce
Part Expansion minimized Adhesive Cure through adhesive cure
Adhesive Temp Cure % 100%
) Adhesive fully cured
DegC OVEN Ramp Up Cure Cure% Temp ( Temp
Time (Mins)
Aston Martin DB11, GALM, Birmingham, 2017 91 Architecture Joining Concept –Bill of Process to achieve Joint Perforamce
Adhesive Cure
Adhesive Temp Cure % 100% )
DegC Controlled part contraction OVEN Ramp Up Cure Cool Down Cure% Temp ( Temp
Time (Mins)
Aston Martin DB11, GALM, Birmingham, 2017 92 Manufacturing Assembly Sequence – Framing
Underframe
Oven Framing
Aston Martin DB11, GALM, Birmingham, 2017 93 Manufacturing Framing Joining Summary
39m of cold cure BETAFORCETM PU adhesive
Allows +/- tolerance compensation through bond squeeze out to enable position of panels to be set independently of underframe variability.
Aston Martin DB11, GALM, Birmingham, 2017 94 ®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow! Manufacturing Assembly Sequence – Framing
Aston Martin DB11, GALM, Birmingham, 2017 95 Assembly Sequence – Closures
Underframe
Oven Framing Closures
Aston Martin DB11, GALM, Birmingham, 2017 96 Manufacturing Assembly Sequence – Closures
Aston Martin DB11, GALM, Birmingham, 2017 97 Manufacturing Assembly Sequence Paint Process
Process: • Low temperature paint cycle (90°). • Whole body including hang-ons and trim items painted together
Benefits: • No body variation introduced through paint process • Allows hand polishing to achieve mirror finish • No colour mismatch
Aston Martin DB11, GALM, Birmingham, 2017 98 DB11 – Project Mission
Architecture
Manufacturing
Summary
Aston Martin DB11, GALM, Birmingham, 2017 99 Reviews
“The Aston Martin DB11 spearheads a completely new model range explosion by Aston. And it's brilliant“ Autocar
“Even on this initial showing the new DB11 is clearly the best Aston Martin in decades“ Auto Express
“The best drive of my career. As unique as it is beautiful… to call the DB11 brilliant is an understatement” The National Post
“There are no cracks to paper over with the DB11, no eccentricities to excuse. It's the best, most completely resolved new Aston Martin in the company's history.” Motor Trend
Aston Martin DB11, GALM, Birmingham, 2017 100 Aston Martin DB11, GALM, Birmingham, 2017 101