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

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ULSAB parts list (cont.) Material Material Part Grade Thickness No Part Name (MPa) (mm) 105 Rail Fender Support Inner LH 420 1.20 106 Rail Fender Support Outer RH 350 0.90 107 Rail Fender Support Outer LH 350 0.90 108 Reinf Front Rail RH 350 1.00 109 Reinf Front Rail LH 350 1.00 110 Plate Rear Spring Upper (2-Req’d) 350 2.00 115 Reinf Panel Dash Brake Booster 350 1.00 116 Assy Bracket Rear Shock Absorber Mount RH 350 2.00 117 Assy Bracket Rear Shock Absorber Mount LH 350 2.00 120 Reinf Floor Front Seat Rear Center 350 1.20 122 Assy Reinf Rear Seat Inner Belt Mount (2-Req’d) 350 2.00 128 Bracket Member Pass Through Lower (2-Req’d) 350 1.00 130 Bracket Member Pass Through Upper Front 350 1.00 136 Reinf Panel Dash Upper 350 1.00 140 Pan Rear Floor 210 0.70 142 Assy Reinf Hinge Decklid (2-Req’d) 350 1.50 144 Reinf A-Pillar RH 350 1.50 145 Reinf A-Pillar LH 350 1.50 152 Bracket Member Pass Through Upper Rear 350 1.00 164 Assy Closeout Fender Support Rail RH 350 1.00 165 Assy Closeout Fender Support Rail LH 350 1.00 170 Reinf Rail Dash RH 350 1.30 171 Reinf Rail Dash LH 350 1.30 172 Assy Reinf Cowl Lower 350 1.00 176 Hinge Base RH (2-Req’d) 280 n/a 177 Hinge Base LH (2-Req’d) 280 n/a 178 Hinge Stem 119 (2-Req’d) 280 n/a 179 Hinge Stem 141 (2-Req’d) 280 n/a 180 Bracket Trailing Arm Mount RH 350 2.00 181 Bracket Trailing Arm Mount LH 350 2.00 188 Brace Radiator (2-Req’d) 350 0.80 190 Assy Reinf Seat Belt Retractor Rear (2-Req’d) 350 1.20 ULSAB Final Report 13
14 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 14 and 15: 1.2 Design philosophy and architect
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 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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