5066 Route 222
Valcourt, QC, Canada, J0E 2L0
To reduce vehicle weight and thereby cut energy consumption, Verbom used the thinnest materials possible while preserving mechanical property integrity. Structural adhesive assembly allows for the use of very thin sheet metal, and unlike welding, it does not alter the characteristics of the alloy. It also allows for the dispersion of the stress over a larger area.
We combined this technology with a honeycomb matrix made of polypropylene that was “sandwiched” between two aluminum sheets. The result was a lightweight and inexpensive rigid wall structure. Verbom then developed a method for numerically modeling this type of assembly to predict resistance under different loading scenarios.
- At correlation tests, a load of 3000 lb (the weight of a small car) was supported with a sandwich wall of 4 ft. x 12 in. x 2 in.
Our extensive knowledge of sheet metal forming allowed us to propose a new welded alternative to a manufactured part that was relatively expensive. The finite element analysis, performed by Verbom, on the ATV chassis loads allowed us to achieve the equivalent mechanical strength, while significantly reducing production costs and product weight.
Verbom designed and built the new sheet metal tooling, produced the stampings and assembled the in-process parts with robotic welding.
- 50% weight reduction
Verbom was mandated to design train seats in stainless steel and fiberglass with a tubular steel structure. For this major project, several standards and specifications had to be respected: those of the Toronto Transit Commission (TTC), the Chicago Transit Authority (CTA), the American Public Transportation Association (APTA), and the Railway Passenger Car Inspection & Safety Rule.
The project also included tolerance studies to ensure a robust/repeatable assembly during production. In addition to performing the finite element analysis, we had to perform over 30 different cycling tests in the laboratory to validate the mechanical strength and life of the components. All technical reports demonstrating specification compliance were written by Verbom, with the goal of having several types of seats for this rail project approved by the client.
- 30 types of laboratory tests
Verbom can manage all aspects of a tooling program. From strip design through final PPAP, Verbom can take the lead in part processing, tolerance feasibility studies, check fixture design, tooling design and transfer automation.
Automated transfer tools for a floor tunnel reinforcement. Verbom managed the entire tooling process and development.
Réservoir essence BRP
Utilizing its FEA experience with Autoform, Verbom offers product development services for many clients including tools used in the manufacture of fuel tanks for hybrid sports vehicles.
With over 12 years experience in the manufacturing of heat and acoustic shields, Verbom is able to offer customized industrial solutions for 1100 aluminum, aluminized steel, or stainless steel.
- 4 layers. Two layers of 0.4 mm thick 1100-0 aluminum, a 6 mm insulating fibre, and a 0.1 mm micro-perforated aluminum layer.
Design and manufacture for a range of tools including large, single-layer heat shields with complex geometries and 100% hemmed edges.
The design proposed by the client led us to push the boundaries of shaping stainless steel. The technical procedure required a highly specialized workforce. The contour of the seat is fully hemmed, which increases rigidity and eliminates sharp edges. 3D laser cutting operations are integrated into the forming press process, a unique way to achieve the quality desired by the client.
- 800 hours of digital simulation and 12 operations
Verbom is a proud partner of Bombardier Transportation in executing the outer covering of the new STM subway cars. This project includes one of the largest aluminum parts manufactured by superplastic forming in the world, a double window frame of 152 in. x 57 in., and panels formed by conventional methods. All parts are delivered by just-in-time methods, ready to be integrated and bonded. Each car has 22 parts, of which 8 are superplastically formed.
- One of the biggest parts manufactured by aluminium superplastic forming in the world, measuring 152 in. x 57 in.
In collaboration with Bombardier Aerospace (official sponsor of the Games), Verbom developed and produced the Olympic Torch for the 2010 Winter Games. Verbom contributed to the redesign of the torch to allow for production.
- 17000 torches manufactured.
Understanding the final assembly quality was dependant upon sub component quality, Verbom entirely developed the welded assembly. Using its expertise in sheet metal and robotic welding technologies, Verbom was able to minimize weight and cost.
- 40% cost reduction