Auto/Steel Partnership - American Iron and Steel Institute

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Correlation Studies LIGHTWEIGHT FRONT END STRUCTURE Phase I Final Report Structural Performance Targets The coefficients of correlation gave a good indication of relationships of occupant parameters (HIC and chest acceleration) with vehicle accelerations (engine, brake caliper, dash, seat peak and seat average acceleration) as shown in Figures 3.7 and 3.8. All occupant parameters showed positive correlation with all vehicle accelerations (except for chest acceleration with seat peak acceleration, which yielded a small negative correlation). Occupant parameters showed the highest correlation with brake caliper acceleration. However, the brake caliper data was suspect and available for fewer vehicles. The correlation was much higher with seat average acceleration as compared to seat peak acceleration. Correlation Coefficient Correlation Coefficient 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Engine Dashpanel Seat Max Seat Ave Figure 3.7: Correlation of HIC with Vehicle Accelerations Engine Dashpanel Seat Max Seat Ave Figure 3.8: Correlation of Chest Acceleration with Vehicle Accelerations Auto/Steel Partnership 34
Structural Targets LIGHTWEIGHT FRONT END STRUCTURE Phase I Final Report Structural Performance Targets The review of the NCAP and IIHS offset crash data has lead to a set of structural performance targets that will provide a favorable environment for achieving a ‘double 5-star’ rating in NCAP and an ‘overall good’ rating in IIHS tests (Ref. 1). It can be inferred from the test data that the strongest correlation of the occupant response was with the average seat acceleration (Figures 3.5- 3.8). Consequently, the acceleration pulse at the B-Pillar was used to characterize the occupant response in 35mph full frontal NCAP test by OEMs, since the occupant experiences this acceleration (deceleration). In all the test data collected from NHTSA , the location of the accelerometer was either at the rear of the front seat near the rocker or at the center of the floor right behind the front seats. The responses at these locations are essentially the same as that at the B-Pillar on rocker. Based on the OEM expert’s input, a target NCAP B-Pillar pulse that ramps up to 26g within 8ms and stays below 26g, is presented in Figure 3.9. This target pulse, which was front-loaded in terms of achieving higher acceleration in the first 8ms, would ensure lower peak between 40ms and 80ms, which would reduce the occupant injury. The actual curve would have a number of peaks and valleys at various intervals depending on the frontend structural architecture, stiffness and energy absorption mechanism. The bumper deformation and initial rail crush would define the early phase of the B-Pillar pulse. The following phase is influenced by the rail and cradle design and energy absorption mechanism within the allowable crush space. The response in the final phase is influenced largely by the tire impact and A/B pillar stiffness. It may be noted that even though the objective of the targets was to ensure 5-star and good rating for the baseline model, a more stringent upper limit on B–pillar pulse would lead to innovative structural concepts, material challenges and new manufacturing techniques. The maximum intrusion targets for the IIHS test are shown in Figure 3.10. The target values for the left, center and right footwell are 12cm, 13cm, and 14cm respectively. In addition, there is a target of 5 cm for AB closure. The intrusion targets are simply the minimum intrusions observed in the IIHS test data. Other intrusion targets were not considered as the FE model did not have the desired details, such as brake pedal and steering column. Auto/Steel Partnership 35
Page 1 and 2: Auto/Steel Partnership
Page 3 and 4: Contents Introduction..............
Page 5 and 6: Formability .......................
Page 7 and 8: LIGHTWEIGHT FRONT END STRUCTURE Pha
Page 9 and 10: Structural Performance Targets [3]
Page 11 and 12: Formability Requirements [8] LIGHTW
Page 13 and 14: Design Space LIGHTWEIGHT FRONT END
Page 21 and 22: Initial Front End Package LIGHTWEIG
Page 25 and 26: Upgraded Front End Package LIGHTWEI
Page 27 and 28: Figure 2.4: Topological Changes to
Page 35 and 36: Seat/floor panel peak acceleration
Page 37: HIC Chest peak acceleration (g) 100
Page 43 and 44: Bumper Design LIGHTWEIGHT FRONT END
Page 45 and 46: umper rail joint. Case Bumper Beam
Page 55 and 56: B- Pillar Acceleration (g) 30.0 25.
Page 59 and 60: X - Acceleration (g) 35.00 30.00 25
Page 63 and 64: 35 30 25 20 15 10 5 0 -5 Figure 4.1
Page 71 and 72: Parametric Study / LIGHTWEIGHT FRON
Page 73 and 74: Results Summary LIGHTWEIGHT FRONT E
Page 77 and 78: * 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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LIGHTWEIGHT FRONT END STRUCTURE Pha
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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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S. No. Part Name Part ID LH Part ID
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Description Torsional Stiffness (N-
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X-Accel 35 30 25 20 15 10 5 0 LIGHT
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S. No Part Name DOE Baseline LIGHTW
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References 1) Phase I Structural Pe
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Figure 8.2: Drawbeads Location Figu
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Figure 8.7: Formability - Dash Pane
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Figure 8.11: Formability - Rocker I
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Figure 8.18: Formability - Rail Inn
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Figure 8.47: Minor Strain Figure 8.
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Figure 8.56: Front Rail Inner - Maj
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Simulation Results Figure 8.60: Fro
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Cost Model LIGHTWEIGHT FRONT END ST
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Knowledge Base LIGHTWEIGHT FRONT EN
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Table of Contents 3 Lightweight Fro
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List of Tables 5 Lightweight Front
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4. Results Summary 7 Lightweight Fr
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Table 2: Grade and Gauge Summary of
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FE Model Validation (4), (5), (6) 1
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6. Rail Concept Development Three r
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Best Hydroformed Design The Hydrofo
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Best Stamped Design The Stamped Des
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Figure 11: Bumper Assembly 19 Light
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Figure 14: Stamped Rail and Attache
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23 Lightweight Front End Structure
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B Pillar X-Acceleration (g) . 40 35
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8. Knowledge Base 27 Lightweight Fr
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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
Page 1033 and 1034:
Corrected Displacement in mm Correc
Page 1035 and 1036:
Static Stiffness DOE Response Surfa
Page 1037 and 1038:
Table of Contents 3 Static Stiffnes
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Figure 1: Bumper Figure 2: LH Rail
Page 1041 and 1042:
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
Page 1047 and 1048:
Dynamic Stiffness DOE Response Surf
Page 1049 and 1050:
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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