1. The IPM GROUP Farmington Hills, Michigan

2. Contact us Beni Dror 27003 Hills Tech Drive Farmington Hills, MI 48331 Tel: 248 489 9490, Fax: 248 479 0771 e-mail:bdror@ipmworld.combdror@ipmworld.com Web:www.ipmworld.comwww.ipmworld.com Mail Address: P.O.Box 252223 West Bloofield, MI 48325

3. Tactical Wheeled Vehicle Weight Reduction Initiative May, 2004 By International Projects Management (I.P.M) LLC Phone: 248 489 94 90

4. Preamble The attached are Examples of an on going weight reduction initiative for the HUMVEE.

5. PROGRAM Selected Components were analyzed to re-engineered to reduction weight by 15%-20% Brackets, Brackets Supports & Transmission Supports.

6. Potential Additional Components Under consideration: Alternator support bracket Chassis beams Engine components

7. Material and Manufacturing Method Selection Selecting the most appropriate material and manufacturing methods according to the part loading and stiffness. Special welding processes of high strength steel sheet More Accurate Casting process to reduce tolerances

8. Using FEA methods Using Finite Element Analysis enables us to refine the stress distribution under more realistic load application and attachment conditions, eliminating the inherent conservatism present in the original calculations. Material lightly loaded can then be safely trimmed from the original part.

9. Examples of FEA used for weight reduction. Part No. 12338191- Spring Seat: from 10.9 lbs to 9.4 lbs Part No. 12469497- Alternator Support: from 25.3 lbs to 21 lbs Part No. 12469498- Compressor Bracket: from 9.8 lbs to 8.1 lbs

10. Stress Report Abstract Part No. 12338191 Compiled Name: J. Hornstein Title: Stress Engineer Checked Name: J. Hornstein Title: Stress Engineer Approved Name: Dr Fredy H. Ornath Title: CEO Materials Systems

11. 1 Subject: Spring Seat, Front, Stress Analysis 2Scope The scope of this report is to compare the strength of the proposed-design to the current design of the subject part under the same stipulated set of external loads. Currently the part is a low alloy, steel sheet (Ftu = 60 ksi) welding assembly while the new design is a casting made of ductile iron of higher strength (Ftu = 100 ksi). 3Abstract A coarse FEM of the current (welded) part was created and subjected to the stipulated set of applied loads. The internal loads, (reactions at the rail attachment and the part displacements and stresses) were calculated. The geometry of this model was then modified to represent the proposed design, retaining the loading and reaction system and the internal loads were calculated again. A strength comparison was then performed considering both internal loads and material properties and a safety factor for the proposed part was calculated when applicable. 4Conclusions and Recommendations The maximum calculated stresses in the current part are exceeding the UTS of the material in the attachment flanges, which is attributable to the inherent conservatism of the analysis. On the assumption that the part had passed the certification tests this should not be a matter of concern. While the strength of the proposed part is exceeding the strength of the current part, because of the material’s low elongation (3% vs. 22% for the current design) it is recommended to eliminate hot spots of tensile stresses above 100000 psi by extending the lower bosses all the way to the horizontal flanges (see Figure 2.1.1 on the next page) 5References The contents list of the full stress report, available at materials systems ltd, is given on page 2.1.4.

12. Current 12338191 – image

13. Current 12338191 - welding

14. New 12338191 - casting

15. 12338191 – Welding – FE Model plot

16. 12338191 – Casting – FE Model plot

17. 12338191 – Welding – FE Results plot

18. 12338191 – Casting – FE Stress plot

19. Part No. 12338191 Stress Report: Open 12338191_Stress_Report_Abstract.doc

20. 12469497(R) and 12469498(L)

21. Stress Report Abstract Part No. 12469498 Compiled Name: J. Hornstein Title: Stress Engineer Checked Name: J. Hornstein Title: Stress Engineer Approved Name: Dr Fredy H. Ornath Title: CEO Materials Systems

22. 12469498 – Original part New Part: Weight reduction accomplished by opening cutouts in original part

23. 12469498 – Original - FEM

24. 12469498 – Redesigned - FEM

25. Part No. 12469498 Stress Report Open 12469498_Stress_Report_Abstract.doc Note:Aluminium Cast Alloy (e.g. 300 Series Aluminium Cast Alloy, MIL-HDBK-5G chapter 3.9) could offer acceptable strength, while reducing the part weight to a third of the current 9.8 lbs

26. Stress Report Abstract Part No. 12469497 Compiled Name: J. Hornstein Title: Stress Engineer Checked Name: J. Hornstein Title: Stress Engineer Approved Name: Dr Fredy H. Ornath Title: CEO Materials Systems

27. 12469497 – Redesigned part Weight reduction accomplished by opening cutouts in original part

28. 12469497 – Redesigned - FEM

29. Part No. 12469497 Stress Report Open 12469497_Stress_Report_Abstract.doc Note:Aluminium Cast Alloy (e.g. 300 Series Aluminium Cast Alloy, MIL-HDBK-5G chapter 3.9) could offer acceptable strength, while reducing the part weight to a third of the current 25.3 lbs