UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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1.2 Design philosophy and architecture 1.3 Packaging PES determined to employ an holistic philosophy toward design early in the design process. This holistic approach treats the body structure as an integrated system rather than an assembly of individual components, emphasizing total body analysis. Through each iterative step, sophisticated computer re-analysis confirms the effectiveness of the latest optimizations. The holistic approach also allows evaluation of how other areas are affected by these changes and where future optimization opportunities exist. This approach promotes weight savings and improved structural integrity by enabling engineers to reduce weight in certain areas while strengthening strategic locations. The net effect is the creation of a more efficient structure. PES investigated various concepts to develop the optimum ULSAB body structure. Some of these included full frame, space frame, unibody and hybrid solutions. Criteria for the structures under consideration were significant weight savings potential, opportunity to achieve performance targets and assembly possibilities in future full volume production body shops. Early in the project PES engineers eliminated the full frame concept because it offered no significant mass saving opportunities. They also doubted that the full frame would meet ULSAB’s structural performance criteria and were concerned about high investment costs for assembly. Although a spaceframe was considered, it was ultimately eliminated because it was not considered as mass efficient as other approaches. The PES team ultimately narrowed its investigation to two structures—a unibody and a hydroform-intensive body structure—finally settling on creating a unibody or monocoque vehicle with key hydroformed parts. The first step in packaging was to define the vehicle concept type, exterior and interior dimensions and main components. With these package definitions, package drawings were created and structural hard points defined. ULSAB did not save mass through downsizing: its wheelbase is 2700 mm; vehicle width is 1819 mm; and vehicle length is 4714 mm. ULSAB Final Report 3
4 Package specifications for ULSAB are: ULSAB package body type 4-door sedan headroom 994/932 mm front/rear wheelbase 2700 mm leg room front/rear 1043/894 mm overall length 4714 mm shoulder room f/r 1512/1522 mm overall width 1819 mm cargo volume 490 liters curb weight 1350 kg engine type 3 liter V6 passenger 5 drive front radiator size 0.252 m2 exhaust system single routing battery 280 X 170 suspension McPherson (in mm) X 170 front suspension rear twist beam tire size (f & r) 195/60R15 spare tire space saver fuel tank volume 65 liters steering rack & pinion The ULSAB package drawings comprehend all essential parts of the structure interior. Criteria for interior design included visibility, obscuration by the pillars, head clearance and seat belt anchors. In the engine compartment, the engine, gearbox, exhaust system, radiator and battery were used to define space for the structural members of the front body structure. ULSAB package drawing side view ULSAB Final Report
Page 2 and 3: UltraLight Steel Auto Body Final Re
Page 4 and 5: Contents Preface v Introduction vii
Page 6: Preface One of the challenges in re
Page 9 and 10: viii Validation Results During the
Page 12 and 13: 1.1 Benchmarking ULSAB Final Report
Page 16 and 17: ULSAB package drawing front view UL
Page 18 and 19: 1.5 Material selection The selectio
Page 20 and 21: Steel sandwich material was chose f
Page 22 and 23: ULSAB parts list Material Material
Page 24 and 25: ULSAB parts list (cont.) Material M
Page 26 and 27: 280 MPa 2.1 Materials 210 MPa ULSAB
Page 28 and 29: Tailored blank usage Tailored blank
Page 30 and 31: 2.2 Processes 2.1.3 Steel sandwich
Page 32 and 33: 2.2.2 Assembly laser welding Sheet
Page 34 and 35: 3.1 Early involvement 3.2 Tooling 3
Page 36 and 37: Floor complete assembly: the rear r
Page 38 and 39: ULSAB Final Report 3.5.2 Adhesive b
Page 40 and 41: 4.1 Validation 4.2 CAE Analysis 4.
Page 42 and 43: ULSAB Final Report All simulations
Page 44 and 45: ULSAB Final Report The offset barri
Page 46 and 47: ULSAB Final Report Analysis was set
Page 48 and 49: ULSAB Final Report Side impact set
Page 50 and 51: 4.3 Physical testing ULSAB Final Re
Page 52 and 53: Frequency Hz Model Analysis ULSAB S
Page 54 and 55: 5. Economic Analysis Although light
Page 56 and 57: 5.3 Model scope 5.4 ULSAB results U
Page 58 and 59: 5.4.3 Investments 5.5 Sensitivity a
Page 60 and 61: Comparison of ULSAB with Year 2000

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