Auto/Steel Partnership - American Iron and Steel Institute

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LIGHTWEIGHT FRONT END STRUCTURE Phase I Final Report Formability Proposal Hence, it was suggested that the part be cut into two pieces, as shown in Figure 8.67, and welded together. The right hand and left hand parts were double attached as shown in Figure 8.68. Figure 8.67: Skirt Cut into Two Pieces Figure 8.68: Skirt Double Attached (Cut into Two Pieces) Conclusion The proposed concept of cutting the skirt into two pieces reduced the draw depth significantly and easily balanced the shape of the die. DOE-based parametric study showed that there was no significant improvement in NCAP performance by upgrading the skirt material. Hence, incremental analysis was not performed on the skirt. Auto/Steel Partnership 194
LIGHTWEIGHT FRONT END STRUCTURE Phase I Final Report Formability Conclusions The 1st cross-member was the most difficult part to form with DP700/1000 material. The initial product design was evaluated with several different forming processes and draw die designs. Significant wrinkling and splitting was observed on all the try-outs. It was concluded that product modification was needed in order to improve the formability of the part. With product concession and process optimization, the part was rendered formable. Front rail inner/outer were formable using a regular three-piece-stretch draw. Minor product modification was needed on rail outer in order to improve the panel quality. DOE-based parametric study showed that there was no significant improvement in NCAP performance by upgrading the skirt material. A brief discussion on the forming issue of the skirt is included in this report. Both equipment cost and spring-back condition were taken into account when developing the forming process and die concept. Auto/Steel Partnership 195
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Auto/Steel Partnership
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Contents Introduction..............
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Formability .......................
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LIGHTWEIGHT FRONT END STRUCTURE Pha
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Structural Performance Targets [3]
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Formability Requirements [8] LIGHTW
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Design Space LIGHTWEIGHT FRONT END
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Initial Front End Package LIGHTWEIG
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Upgraded Front End Package LIGHTWEI
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Figure 2.4: Topological Changes to
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Seat/floor panel peak acceleration
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HIC Chest peak acceleration (g) 100
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Structural Targets LIGHTWEIGHT FRON
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Bumper Design LIGHTWEIGHT FRONT END
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umper rail joint. Case Bumper Beam
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B- Pillar Acceleration (g) 30.0 25.
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X - Acceleration (g) 35.00 30.00 25
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35 30 25 20 15 10 5 0 -5 Figure 4.1
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Parametric Study / LIGHTWEIGHT FRON
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Results Summary LIGHTWEIGHT FRONT E
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* Baseline values Parameters D.O.E.
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* Baseline values LIGHTWEIGHT FRONT
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NCAP Parametric Study LIGHTWEIGHT F
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acc (g) 50 40 30 20 10 0 Max B-Pill
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Normalized Grade Normalized Grade 7
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Design Variables: Acceleration
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X-Acceleration (g) 35 30 25 20 15 1
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Stiffness (N/m) Stiffness (N/m) 60.
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Normalized SS Normalized SS 50 45 4
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Normalized Grade Normalized Grade 5
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Intrusion (cm) Intrusion (cm) 30.0
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Intrusion (cm) Intrusion (cm) 30 25
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Performance Matrix Computer Aided L
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References 1) Phase I Structural Pe
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Intrusion (cm) X-Acceleration (g) 4
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Design Design Mass Saving (Kg) 0 -
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X-Accel (g) 30 25 20 15 10 5 0 LIGH
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Optimal Design 7 LIGHTWEIGHT FRONT
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S. No Part Name LIGHTWEIGHT FRONT E
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X-Accel (g) 40 35 30 25 20 15 10 5
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Design Design Mass Delta (Kg) Mass
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Page 149 and 150: Description Torsional Stiffness (N-
Page 151 and 152: LIGHTWEIGHT FRONT END STRUCTURE Pha
Page 153 and 154: X-Accel 35 30 25 20 15 10 5 0 LIGHT
Page 155 and 156: S. No Part Name DOE Baseline LIGHTW
Page 157 and 158: References 1) Phase I Structural Pe
Page 161 and 162: Figure 8.2: Drawbeads Location Figu
Page 163 and 164: Figure 8.7: Formability - Dash Pane
Page 165 and 166: Figure 8.11: Formability - Rocker I
Page 169 and 170: Figure 8.18: Formability - Rail Inn
Page 189 and 190: Figure 8.47: Minor Strain Figure 8.
Page 193 and 194: Figure 8.56: Front Rail Inner - Maj
Page 195 and 196: Simulation Results Figure 8.60: Fro
Page 197: LIGHTWEIGHT FRONT END STRUCTURE Pha
Page 201 and 202: Cost Model LIGHTWEIGHT FRONT END ST
Page 205 and 206: Knowledge Base LIGHTWEIGHT FRONT EN
Page 217: LIGHTWEIGHT FRONT END STRUCTURE Pha
Page 220 and 221: Table of Contents 3 Lightweight Fro
Page 222 and 223: List of Tables 5 Lightweight Front
Page 224 and 225: 4. Results Summary 7 Lightweight Fr
Page 226 and 227: Table 2: Grade and Gauge Summary of
Page 228 and 229: FE Model Validation (4), (5), (6) 1
Page 230 and 231: 6. Rail Concept Development Three r
Page 232 and 233: Best Hydroformed Design The Hydrofo
Page 234 and 235: Best Stamped Design The Stamped Des
Page 236 and 237: Figure 11: Bumper Assembly 19 Light
Page 238 and 239: Figure 14: Stamped Rail and Attache
Page 240 and 241: 23 Lightweight Front End Structure
Page 242 and 243: B Pillar X-Acceleration (g) . 40 35
Page 244 and 245: 8. Knowledge Base 27 Lightweight Fr
Page 246 and 247: 9. Manufacturing 29 Lightweight Fro
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Thinning < 10% : Design Feasible 31
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Original Prototyping Processes Fina
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Figure 22: Front Rail Inner/Outer F
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Figure 26: Bumper Assembly 37 Light
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Dimensional Tolerance Analyses 39 L
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Figure 32: Bumper Tolerances 41 Lig
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Figure 34: Weld Fixtures Figure 35:
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Figure 37: NCAP Test - Front View F
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Figure 41: NCAP Test - Bumper Close
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12. Conclusions 49 Lightweight Fron
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14. Appendix A: FE Model Model mass
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15. Appendix B: Milestone Reports 1
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16. Appendix C: A/SP Reports A/SP E
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Abstract 2 Competitive Benchmarking
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List of Figures 4 Competitive Bench
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6 Competitive Benchmarking Rigid Fi
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8 Competitive Benchmarking The foll
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Figure 5: Rail Deformations at 0ms:
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Figure 9: Rail Deformations at 40ms
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3.1. Design 0 This design served as
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4. Subsystem Comparison 16 Competit
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Competitive Benchmarking Figure 16:
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5. Conclusions 20 Competitive Bench
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8. Appendix A: Animations 22 Prelim
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Abstract 2 Competitive Benchmarking
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Competitive Benchmarking List of Fi
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1. Objectives 6 Competitive Benchma
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Model/Make Front Rail Cross- Table
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2002 Honda Accord � Straight rail
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2003 Toyota Corolla 4 Dr Sedan �
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5. Conclusions The following design
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Competitive Benchmarking 8. Appendi
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2001 VW Golf Figure 11: VW Golf - R
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Figure 13: VW Golf - Front Rails (i
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2002 VW Passat Figure 15: VW Passat
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2001 Mercedes Benz S-500 24 Competi
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Figure 19: Mercedes Benz S-500 - Fi
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Figure 22: Honda Accord - Front Rai
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2002 Honda Civic Figure 24: Honda C
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Figure 27: Honda Civic - Front Rail
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2003 Honda Pilot Figure 29: Honda P
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Figure 33: Lexus LS430 - First Cros
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Front Rail Rear Rail Front Rail Fig
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Figure 39: Toyota Camry - Bumper Cr
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2003 Saturn Ion Figure 42 LH front
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2002 Saturn VUE Figure 45: LH front
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2002 Lincoln LS Figure 49: Lincoln
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Abstract 2 Rail Concept Development
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List of Figures 4 Rail Concept Deve
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3. Existing Rail Architecture 6 Rai
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Figure 3: LH Rail Assembly 8 Rail C
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Figure 5: Bumper Assembly 10 Rail C
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Rail Concept Development European p
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Rail Concept Development sweep, wid
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4. Best Stamped Design 16 Rail Conc
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Rail Concept Development The rail c
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Figure 14: Additional Reinforcement
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Rail Concept Development Phase I st
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5. Best Hydroformed Design 24 Rail
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Figure 20: LH Rail - Plan View 26 R
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7. Conclusions 28 Rail Concept Deve
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Validated FE Models Milestone 5 Lig
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Table of Contents 3 Validated FE Mo
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1. Objectives 5 Validated FE Models
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Figure 1: NCAP Full Vehicle FE Mode
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4. NCAP Response Figure 4: Deformat
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B Pillar X-Acceleration (g) . B Pil
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B Pillar X-Velocity (mm/sec) . B Pi
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5. IIHS Response Figure 14: Deforma
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Figure 17: Deformation of Front End
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8. Appendix A: Animations 19 Valida
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Component Name ID Property Name ID
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23 Validated FE Models tir2.l 71113
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25 Validated FE Models trqbox1.r 11
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27 Validated FE Models ailctr2.l 12
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29 Validated FE Models foam 9006002
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31 Validated FE Models tipof bin 90
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Abstract 2 Enhanced FE Models This
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List of Figures 4 Enhanced FE Model
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3. Model Modifications 6 Enhanced F
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Figure 4: IP Coarse Mesh Model Figu
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Figure 8: Windshield Coarse Mesh Mo
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Figure 11: NCAP Full Vehicle FE Mod
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Table 5: NCAP Crash Events Time (ms
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6. Conclusions 22 Enhanced FE Model
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9. Appendix A: Animations 24 Enhanc
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Component Name 26 Enhanced FE Model
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28 Enhanced FE Models tir2.l 71113
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30 Enhanced FE Models trqbox1.r 110
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32 Enhanced FE Models ailctr2.l 128
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34 Enhanced FE Models foam 90060029
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36 Enhanced FE Models tipof bin 900
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Abstract 2 DOE FE Models This repor
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List of Figures 4 DOE FE Models Fig
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were penetrating the ground. Fricti
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Interference of parts was reduced s
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Figure 1: Output Locations for NCAP
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Figure 5: IP Fine Mesh Model Figure
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Figure 9: Windshield Fine Mesh Mode
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Figure 13: NCAP Full Vehicle FE Mod
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DOE FE Models Table 6: NCAP Crash E
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Intrusion (mm) 40 20 -20 -40 -60 26
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9. References 1) Validated FE Model
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11. Appendix B: Summary of FE Model
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DOE FE Models MTG1 60412 SectShll10
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DOE FE Models can.1 61106 90060011
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DOE FE Models outer.1 61209 9006011
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DOE FE Models fbhplrrnf1.r 61624 Se
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DOE FE Models out_front_lh_doo 6204
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Abstract 2 Concept 1 Subsystem Desi
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List of Figures 4 Concept 1 Subsyst
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Figure 1: Subsystem of Concept 1 De
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Concept 1 Subsystem Design The subs
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Internal Energy (kN-mm) 16000 14000
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6. References 1) ULSAB Model with U
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Concept 1: Preliminary Design Miles
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Table of Contents 3 Concept 1: Prel
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1. Objectives 5 Concept 1: Prelimin
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Figure 2: Reinforcements Removed 7
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Figure 4: New Bumper Design 9 Conce
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4. FE Model - Output Location Summa
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5. NCAP Response The figures below
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6. IIHS Response IIHS intrusions ar
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7. Conclusions 19 Concept 1: Prelim
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10. Appendix A: Animations 21 Conce
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Concept 1: Preliminary Design rrcrd
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Concept 1: Preliminary Design ep_70
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Concept 1: Preliminary Design modpl
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Concept 1: Preliminary Design drlwh
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Concept 1: Preliminary Design accl.
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Concept 1: DOE Study Milestone 11 L
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Table of Contents 3 Concept 1: DOE
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1. Objectives 5 Concept 1: DOE The
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Concept 1: DOE Figure 4-6 show the
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6. Conclusions 11 Concept 1: DOE An
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9. Appendix A: Concept1 Baseline FE
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Concept 1: DOE MTG1 60412 SectShll1
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Concept 1: DOE can2 61105 90060010
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Concept 1: DOE bintongue 61208 9006
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Concept 1: DOE fbhplrrnf1.l 61623 S
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23 Concept 1: DOE SpotWelds 62039 N
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Abstract 2 Concept 1: Final Design
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List of Figures 4 Concept 1: Final
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Concept 1: Final Design The Final D
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Part Baseline Design Table 5: Grade
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7. Conclusions 16 Concept 1: Final
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Concept 1: Final Design Component N
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Figure 2: LH Inner & Outer Rails 7
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Figure 4: LH Skirt Reinforcement 9
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Figure 6: New Bumper Design - Close
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13 Concept 2: Preliminary Design Ta
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Abstract 2 Concept 1: Preliminary D
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List of Figures 4 Concept 1: Prelim
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3. DOE Responses 6 Concept 1: Preli
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Concept 2: Final Design Milestone 1
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Table of Contents 3 Concept 2: Fina
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1. Objectives 5 Concept 2: Final De
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Outboard Rail Figure 2: LH Inner &
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Figure 4: New Bumper Design 9 Conce
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Figure 6: Bumper Attachment 11 Conc
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The figures below summarize the NCA
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Concept 2: Final Design Table 6: NC
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7. Conclusions 19 Concept 2: Final
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Concept 1: Preliminary Design lcarn
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Concept 1: Preliminary Design tire1
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Concept 1: Preliminary Design pivot
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Concept 1: Preliminary Design fdrbd
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Concept 1: Preliminary Design rbmpb
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12. Appendix C: Attached Parts Figu
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Figure 24: Front Cradle Mount 36 Co
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Figure 26: Torque Box 38 Concept 1:
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Figure 28: Battery 40 Concept 1: Pr
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Figure 3: LH Rail - Isometric View
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Concept 1: Preliminary Design The r
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Figure 9: New Bumper Design - Half
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Figure 10: Output Locations for NCA
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B Pillar X-Velocity (mm/sec) . 4000
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6. IIHS Response 17 Concept 1: Prel
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Toepan Right Intrusion (mm) A-B Pil
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Concept 1: Preliminary Design tieba
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Concept 1: Preliminary Design upper
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Concept 1: Preliminary Design outer
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Concept 1: Preliminary Design gusse
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Concept 1: Preliminary Design out_r
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Figure 22: Attached Parts - Side Vi
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Figure 25: Suspension Panel 37 Conc
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Figure 27: Rear Cradle Mount 39 Con
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Figure 29: Tie Bar 41 Concept 1: Pr
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Abstract 2 Concept 3: DOE This repo
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List of Figures 4 Concept 3: DOE Fi
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3. DOE Model 6 Concept 3: DOE The D
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Norm SS 30 25 20 Norm SS 15 10 5 0
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Concept 3: Final Design Milestone 1
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Table of Contents 3 Concept 3: Fina
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1. Objectives 5 Concept 3: Final De
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Figure 3: LH Rail - Isometric View
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9 Concept 3: Final Design The rail
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Figure 9: New Bumper Design - Half
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Figure 10: Output Locations for NCA
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B Pillar X-Velocity (mm/sec) . 4000
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6. IIHS Response 17 Concept 3: Fina
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Toepan Right Intrusion (mm) A-B Pil
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25 Concept 3: Final Design tiebar4.
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27 Concept 3: Final Design ai_icebo
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29 Concept 3: Final Design part.15
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31 Concept 3: Final Design rrhdr 61
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12. Appendix C: Attached Parts Figu
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Figure 24: Front Cradle Mount 35 Co
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Figure 26: Torque Box 37 Concept 3:
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Figure 28: Battery 39 Concept 3: Fi
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Bumper Formability Milestone 19 Lig
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Table of Contents 3 Bumper Formabil
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1. Objectives 5 Bumper Formability
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4. Bumper Formability Results 9 Bum
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Target Thinning
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Figure 7: Bumper Outer - FLD Curve
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NCAP DOE Response Surface Milestone
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Table of Contents 3 NCAP DOE Respon
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1. Objectives 5 NCAP DOE Response S
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Figure 2: LH Rail Assembly 7 NCAP D
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Rail Extension 3. NCAP Response Sur
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Abstract 2 IIHS DOE Response Surfac
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List of Figures 4 IIHS DOE Response
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Figure 1: Bumper 6 IIHS DOE Respons
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Outboard Rail Figure 3: LH Inner &
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5. Conclusions 12 IIHS DOE Response
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Final Optimized Design Milestone 22
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Table of Contents 3 Final Optimized
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1. Objectives 5 Final Optimized Des
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Table 3: Static Stiffness Results 7
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Rail Extension Rail Extension Reinf
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5. NCAP Response The figures below
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Abstract 2 Analysis of Vehicle With
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List of Figures 4 Analysis of Vehic
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3. Modifications to Final Design 6
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Figure 2: Front Cradle Mounts Figur
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Figure 6: Rail Extension Welds A ma
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5. NCAP Response 14 Analysis of Veh
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vel (mm/sec) 4000 2000 -4000 -6000
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Table of Contents Section Descripti
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List of Figures Number Title Page 1
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List Of Photographs, Cont'd. Descri
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Purpose This 56 km/h (35 mph) front
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Section 2.0 Impact Test Summary 2-1
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Data Acquisition Explanations The p
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Table 2 General Test and Vehicle Pa
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Test vehicle's target test weight:
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Table 3 Post-Impact Data Test type:
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Figure 2 Load Cell Barrier Configur
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3 7 4 5 3 4 6 5 6 Figure 3 Vehicle
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Figure 4 Vehicle Crush Data Vehicle
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Figure 5 Vehicle Intrusion Measurem
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I L K J M Figure 7 Vehicle Intrusio
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Figure 9 Vehicle Toeboard Measureme
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2 6 7 4 5 3 Figure 10 Camera Positi
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Figure 11 Vehicle Reference Photo T
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Figure A-1 Pre-Test Front View Figu
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Figure A-5 Pre-Test Left Side View
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Figure A-9 Pre-Test Rear View Figur
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Figure A-13 Pre-Test Right Side Vie
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Figure A-17 Pre-Test Overhead View
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Figure A-20 Pre-Test Front Underbod
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Figure A-24 Pre-Test Mid Underbody
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Figure A-28 Pre-Test Rear Underbody
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Figure A-32 Pre-Test Fuel Filler Ne
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Figure A-35 Pre-Test Windshield Vie
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Figure A-39 Pre-Test Right Front Wi
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Appendix C Miscellaneous Test Instr
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Frequency Response Classes SAE J211
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Correlation of Vehicle With New Rai
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3. NCAP Response Correlation of Veh
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acc (g) acc (g) 50 40 30 20 10 0 50
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force (N) 1.0E+06 9.0E+05 8.0E+05 7
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Table of Contents Proteus Guideline
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Table of Contents 1 Introduction...
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1 Introduction Proteus Guidelines T
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Powertrain Front-end Package of Pha
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• LH and RH Pulse - NCAP B-pillar
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7.1 Online Help Click on the Help o
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Add or Delete an Architecture Click
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7.4 Compute Response Scroll down th
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DoE Parameters Click on the Paramet
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Error Plots Click on the Error Grap
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7.5 Load a Design from the Library
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Deleting a User Design Click on the
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7.8 Optimize Design Click on the Op
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Figure 16: Proteus Optimizer Page
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Initial Front-End Package: Phase I
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Initial Front-End Package: Phase I
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1 18 17 4 5 Figure 1: Front-End Par
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18 20 17 8 10 4 5 9 6 Figure 3: Fro
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4/27 9/33 5/28 17/31 6/29 9/30 1/24
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Normalized Grade -13.8 -12.7 700 MP
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Table of Contents 1 Front-End DoE P
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34 Panel Body Side Outer Top & B-Pi
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19 21 17 6 4 18 5 16 9 Figure 1: Fr
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S.N. 1 2 Table 4: Topological Param
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Normalized Grade 500 MPa 2 1 Overal
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4 IIHS Study of Upgraded Front-End
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18/39 4/27 17/ 38 21/42 5/28 6/29 2
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Stamped Design: Phase II Lightweigh
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1 DOE Parts Rail Front Inner/Outer
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3 NCAP/IIHS Studies The NCAP/IIHS D
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4 References 1) DOE FE Models, Mile
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Abstract 2 Static Dynamic Stiffness
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1. Objectives 4 Static Dynamic Stif
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Corrected Displacement in mm Correc
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Static Stiffness DOE Response Surfa
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Table of Contents 3 Static Stiffnes
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Figure 1: Bumper Figure 2: LH Rail
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Rail Extension 3. Model Modificatio
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Figure 6: Final Concept 2 Design BI
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Corrected Theta in degrees Correcte
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Dynamic Stiffness DOE Response Surf
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Table of Contents 3 Dynamic Stiffne
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Figure 1: Bumper Figure 2: LH Rail
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Rail Extension 3. Model Modificatio
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Figure 6: Final Concept 2 Design BI
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5. Conclusions 11 Dynamic Stiffness
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Auto/Steel Partnership - American Iron and Steel Institute

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