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

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Comparison of ULSAB with Year 2000 structure Body Structure Mass: Parts Fabrication: Assembly: Cost: (in $US) ULSAB Final Report ULSAB Year 2000 Net weight (kg) 203 250 Stampings 184 230 Hydroformings 10 0 Purchased parts 9 20 Material utilization 49 55 Direct labor 59 79 Indirect labor 47 36 Parts count: 158 200 Large stampings 11 6 Medium stampings 39 79 Small stampings 44 50 Hydroformings 2 0 Purchased parts 62 65 Die sets: 61 109 Transfer 14 20 Tandem 27 59 Progressive 18 30 Hydroform 2 0 Hits per die set: Transfer 4.1 3.8 Tandem 3.6 3.2 Hits per part: Transfer/tandem combined 2.5 2.5 Direct labor 64 80 Indirect labor 178 210 Number of spot welds 2206 3250 Length (mm) laser weld 18286 0 Number of robots 136 200 Number of laser welders 13 0 Number of assbly stations 114 130 Assembly bldg. area (m2) 20925 30000 Stamped parts 584 609 Hydroformed rail 41 0 Purchased parts 41 41 Assembly 281 329 TOTAL COST $947 $979 49
50 5.7 Conclusion Achieving lightweight and superior performance in a steel body structure can be done at no cost penalty. In fact, it can be less expensive than structures that do not have its benefits. ULSAB demonstrates that reduced weight and superior performance are achievable and affordable. ULSAB Final Report
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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 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
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UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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