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Redesign of 2005 Ford Mustang Hydraulic Engine Mount Paulstra CRC

Redesign of 2005 Ford Mustang Hydraulic Engine Mount Paulstra CRC. Andy Castora Mark Hesselsweet Ryan Saagman Brad VanderVeen.

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Redesign of 2005 Ford Mustang Hydraulic Engine Mount Paulstra CRC

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  1. Redesign of 2005 Ford Mustang Hydraulic Engine MountPaulstra CRC Andy Castora Mark Hesselsweet Ryan Saagman Brad VanderVeen

  2. Paulstra CRC was seeking a new design for the current Ford Mustang engine mount. Paulstra CRC sought an alternative sealing technique, alternative material, and if possible, a lower manufacturing cost for the mount. • A functional prototype engine mount was successfully designed, built, and tested for Paulstra CRC.

  3. 30% glass filled nylon • Compressive rubber seal • Twist lock design • Sonic welded subassembly

  4. Prototypes were built to validate the calculations for the amount of force the plastic tabs could withstand.

  5. Fatigue Testing Fixture • Loads • +300N to –2700 N in Z-direction • At 5Hz to fatigue Decoupler • At 11Hz to fatigue MRE Characterization Fixture • Static • 1500N Preload • 0N to +3000N in Z-direction • Dynamic • 1500N Preload • Dynamic Sweep from 0Hz to 500Hz at various amplitudes

  6. Characterization testing proved that the mount exhibited the designed performance characteristics. • Fatigue life of 335,000 cycles

  7. The 30% glass-reinforced Nylon 6/6 used in the mount, made a cheaper and lighter alternative to the original steel and aluminum design. • The J-Channel design was effective in joining the halves of the mount. • The O-Ring seal around the base of the MRE Assembly effectively sealed the mount from leaking. • The re-designed mount was validated as a feasible concept through fatigue and characterization testing. • For Paulstra, the new mount design is an important step toward alternative materials and future cost reductions.

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