Auto/Steel Partnership - American Iron and Steel Institute

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DOE FE Models MTG1 60412 SectShll10.1 60083 MATL24_210 60052 4.34E-04 1 BRKT_Consol 60413 SectShll15.3 60117 MATL24_210 60052 6.89E-04 1.5 crush_brkt_lwr 60414 SectShll20.1 60088 MATL24_210 60052 0.002868 2 bar2.l 60501 SectShll12.1 60084 MATL24_160 60048 0.001367 1.2 bar2.r 60502 SectShll12.1 60084 MATL24_160 60048 0.001368 1.2 2barreinf 60503 SectShll17 60086 MATL24_340 60049 0.00249 1.7 22678921_256_1 60505 SectShll12.1 60084 MATL24_160 60048 2.43E-04 1.2 22678920_256_1 60506 SectShll12.1 60084 MATL24_160 60048 2.43E-04 1.2 22678921_255_1 60507 SectShll12.1 60084 MATL24_160 60048 1.85E-04 1.2 22678920_255_1 60508 SectShll12.1 60084 MATL24_160 60048 1.85E-04 1.2 seatrein.l 60509 SectShll12.1 60084 MATL24_160 60048 3.45E-04 1.2 seatrein.r 60510 SectShll12.1 60084 MATL24_160 60048 3.46E-04 1.2 tiebar3.l 60601 Sectshll75 60097 MATL24_180 60046 6.78E-04 0.75 tiebar3.r 60602 Sectshll75 60097 MATL24_180 60046 7.22E-04 0.75 tiebar4.l 60603 Sectshll75 60097 MATL24_180 60046 4.27E-05 0.75 tiebar4.r 60604 Sectshll75 60097 MATL24_180 60046 4.44E-05 0.75 lhfanmotor 60605 SectShll20.1 60088 MATL24_181 60047 5.60E-04 2 rhfanmotor 60606 SectShll20.1 60088 MATL24_181 60047 5.40E-04 2 tiebar 60607 SectShll9.1 60082 MATL24_210 60052 0.002278 0.9 tiebar2 60608 SectShll9.1 60082 MATL24_160 60048 0.001152 0.9 radsupport 60609 SectShll10.1 60083 MATL24_160 60048 0.001261 1 rad4 60610 SectShll10.1 60083 MATL24_160 60048 8.32E-06 1 Part_2 60611 SectShll10.1 60083 MATL9_2 60006 0.014989 1 rad2 60612 SectSld900 60121 MAT57rad&cond 60059 0.002656 0 rad1 60613 SectSld900 60121 MAT57rad&cond 60059 0.003782 0 fanshroud 60614 SectShll20.1 60088 MATL24_181 60047 0.007298 2 pt2 60702 SectShll10.1 60083 rigid 60014 0.001123 1 pt3 60703 SectShll10.1 60083 rigid 60014 0.006404 1 pt7 60704 SectShll10.1 60083 rigid 60014 0.001243 1 pt8 60705 SectShll20.1 60088 rigid 60014 0.005065 2 pt10 60706 SectShll10.1 60083 rigid 60014 9.92E-04 1 pt11 60707 SectShll225 60099 rigid 60014 0.001335 2.25 pt13 60708 SectShll10.1 60083 rigid 60014 1.07E-04 1 pt14 60709 SectShll10.1 60083 rigid 60014 0.001639 1 pt19 60710 SectShll10.1 60083 rigid 60014 4.08E-04 1 pt18 60711 SectShll40 60093 rigid 60014 0.007253 4 frtmnt1 60712 SectShll20.1 60088 MATL24_160 60048 1.04E-03 2 frtmnt2 60713 SectShll225 60099 MATL24_160 60048 3.84E-04 2.25 pt9 60714 SectShll100 60104 rigid 60014 0.005277 10 pt12 60715 SectShll80 60095 rigid 60014 0.007011 8 pt16 60716 SectShll40 60093 rigid 60014 0.003234 4 pt17 60717 SectShll30 60094 MATL24_160 60048 0.007696 3 expipefrt 60718 SectShll15.3 60117 MATL24_160 60048 0.003601 1.5 ep_7685 60719 SectShll10.1 60083 rigid 60014 2.83E-04 1 flywheel 60720 SectShll10.1 60083 rigid 60014 7.92E-04 1 ep_4776 60721 SectShll10.1 60083 rigid 60014 4.99E-04 1 ep_7498 60722 SectShll10.1 60083 rigid 60014 0.002605 1 ep_0939 60723 SectShll10.1 60083 rigid 60014 5.79E-04 1 ep_0017 60724 SectShll10.1 60083 rigid 60014 4.50E-04 1 32 Auto/Steel Partnership
DOE FE Models ep_70842 60725 SectShll10.1 60083 rigid 60014 1.84E-04 1 eng_mnt_l_e 60726 SectShll80 60095 MATL24_160 60048 0.002636 8 top_bkt_l_e 60727 SectShll80 60095 MAT24_1111 60045 5.72E-04 8 eng_mnt_r_e 60728 SectShll80 60095 MATL24_160 60048 0.002631 8 top_bkt_r_e 60729 SectShll80 60095 MAT24_1111 60045 1.01E-03 8 eng_deformable 60730 SectShll80 60095 MATL24_160 60048 0.001725 8 62109a_e1 60731 SectShll37 60108 MATL24_160 60048 3.62E-04 3.7 62109a_e2 60732 SectShll37 60108 MATL24_160 60048 1.22E-04 3.7 62109a_e3 60733 SectShll37 60108 MATL24_160 60048 4.00E-04 3.7 62109b_e1 60734 SectShll10.1 60083 MATL24_160 60048 4.06E-04 1 rrmnt_bushing 60735 SectShll20.1 60088 MATL24_160 60048 5.79E-04 2 tire1.l 60801 SectShll20.1 60088 mat1.tirerubber 60007 0.00197 2 tire1.r 60802 SectShll20.1 60088 mat1.tirerubber 60007 0.00197 2 tire3.l 60803 SectShll3.3 60107 MATL24_160 60048 1.00E-03 0.3 tire2.r 60804 SectShll3.3 60107 MATL24_160 60048 1.00E-03 0.3 tir2.l 60805 SectShll7.2 60080 MATL24_160 60048 0.002042 0.7 tire3.r 60806 SectShll7.2 60080 MATL24_160 60048 0.002042 0.7 rim.l 60807 SectShll35 60106 MATL24_600 60056 0.008136 3.5 rim.r 60808 SectShll35 60106 MATL24_600 60056 0.008136 3.5 lwrcntrlarm.l 60809 SectShll30 60094 MATL24_160 60048 0.002294 3 lwrcntrlarm.r 60810 SectShll30 60094 MATL24_160 60048 0.002289 3 lcajnt_2.L1 60811 SectShll30 60094 rigid 60014 6.26E-05 3 lcajnt_2.R1 60812 SectShll30 60094 rigid 60014 6.33E-05 3 driveline 60813 SectShll70 60103 MATL24_340 60049 0.005373 7 lcajnt_2.L2 60815 SectShll30 60094 rigid 60014 2.76E-05 3 lcajnt_2.R2 60816 SectShll30 60094 rigid 60014 2.76E-05 3 fsuspstrut.l 60817 SectShll50 60092 MATL24_160 60048 0.005601 5 fsuspstrut.r 60818 SectShll50 60092 MATL24_160 60048 0.005601 5 crdlbltrnf 60819 SectShll275.1 60102 MATL24_160 60048 3.23E-04 2.75 strclnmend3 60820 SectShll50 60092 rigid 60014 3.64E-04 5 strngrack 60821 SectShll60 60101 MAT24_1111 60045 0.002617 6 strrackends 60822 SectShll60 60101 MATL24_160 60048 0.001165 6 stabbar 60823 SectShll40 60093 MATL24_160 60048 0.004576 4 btray1 60901 SectShll15.3 60117 MATL24_160 60048 0.003147 1.5 btray2 60902 SectShll10.1 60083 MATL24_160 60048 2.19E-04 1 battery1 60903 SectShll5.3 60105 MATL24_160 60048 8.66E-04 0.5 ECM 60904 SectShll10.1 60083 MATL24_160 60048 1.07E-03 1 battery_fill 60905 SectShll10.1 60083 MATL24_160 60048 0.001326 1 fcomptrnf2 60906 SectShll40 60093 MATL24_160 60048 0.002901 4 abs_brkt 60907 SectShll20.1 60088 MATL24_160 60048 4.33E-04 2 brkt_boost 60908 90060072 60042 90060009 60012 0.00385 3 edge 61001 SectShll2.1.1 60077 MAT24_3 60042 1.06E-03 1.35 inner 61002 SectShll3.2.1 60078 MAT24_3 60042 0.005147 0.7 outer 61003 SectShll4.1.1 60079 MAT24_3 60042 0.008252 0.7 MODPLT 61101 90060005 60010 90060020 60041 0.001613 1.5 CSUPT_forw 61102 90060006 60011 90060020 60041 5.32E-04 1.22 can 61103 90060008 60012 90060020 60041 6.77E-04 1.2 can1 61104 90060009 60013 90060020 60041 9.87E-05 1.2 can2 61105 90060010 60014 90060020 60041 1.09E-04 1.2 33 Auto/Steel Partnership
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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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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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Figure 15: Deformation of Front End
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Page 418 and 419: Table 5: NCAP Crash Events Time (ms
Page 420 and 421: Figure 24: Deformation of Front End
Page 422 and 423: 6. Conclusions 22 Enhanced FE Model
Page 424 and 425: 9. Appendix A: Animations 24 Enhanc
Page 426 and 427: Component Name 26 Enhanced FE Model
Page 428 and 429: 28 Enhanced FE Models tir2.l 71113
Page 430 and 431: 30 Enhanced FE Models trqbox1.r 110
Page 432 and 433: 32 Enhanced FE Models ailctr2.l 128
Page 434 and 435: 34 Enhanced FE Models foam 90060029
Page 436 and 437: 36 Enhanced FE Models tipof bin 900
Page 438 and 439: Abstract 2 DOE FE Models This repor
Page 440 and 441: List of Figures 4 DOE FE Models Fig
Page 442 and 443: were penetrating the ground. Fricti
Page 444 and 445: Interference of parts was reduced s
Page 446 and 447: Figure 1: Output Locations for NCAP
Page 448 and 449: Figure 5: IP Fine Mesh Model Figure
Page 450 and 451: Figure 9: Windshield Fine Mesh Mode
Page 452 and 453: Figure 13: NCAP Full Vehicle FE Mod
Page 456 and 457: B Pillar X-Acceleration (g) . B Pil
Page 458 and 459: DOE FE Models Table 6: NCAP Crash E
Page 462 and 463: Intrusion (mm) 40 20 -20 -40 -60 26
Page 464 and 465: 9. References 1) Validated FE Model
Page 466 and 467: 11. Appendix B: Summary of FE Model
Page 470 and 471: DOE FE Models can.1 61106 90060011
Page 472 and 473: DOE FE Models outer.1 61209 9006011
Page 474 and 475: DOE FE Models fbhplrrnf1.r 61624 Se
Page 476 and 477: DOE FE Models out_front_lh_doo 6204
Page 478 and 479: Abstract 2 Concept 1 Subsystem Desi
Page 480 and 481: List of Figures 4 Concept 1 Subsyst
Page 482 and 483: Figure 1: Subsystem of Concept 1 De
Page 484 and 485: Concept 1 Subsystem Design The subs
Page 486 and 487: Internal Energy (kN-mm) 16000 14000
Page 488 and 489: 6. References 1) ULSAB Model with U
Page 490 and 491: Concept 1: Preliminary Design Miles
Page 492 and 493: Table of Contents 3 Concept 1: Prel
Page 494 and 495: 1. Objectives 5 Concept 1: Prelimin
Page 496 and 497: Figure 2: Reinforcements Removed 7
Page 498 and 499: Figure 4: New Bumper Design 9 Conce
Page 500 and 501: 4. FE Model - Output Location Summa
Page 502 and 503: 5. NCAP Response The figures below
Page 504 and 505: B Pillar X-Velocity (mm/sec) . B Pi
Page 506 and 507: 6. IIHS Response IIHS intrusions ar
Page 508 and 509: 7. Conclusions 19 Concept 1: Prelim
Page 510 and 511: 10. Appendix A: Animations 21 Conce
Page 512 and 513: Concept 1: Preliminary Design rrcrd
Page 514 and 515: Concept 1: Preliminary Design ep_70
Page 516 and 517: 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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4. FE Model - Output Location Summa
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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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Figure 2: Output Locations for NCAP
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6. IIHS Response IIHS intrusions ar
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7. Conclusions 16 Concept 1: Final
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10. Appendix A: Animations 18 Conce
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Concept 1: Final Design Component N
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Concept 2: Preliminary Design Miles
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Table of Contents 3 Concept 2: Prel
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1. Objectives 5 Concept 2: Prelimin
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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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B Pillar X-Velocity (mm/sec) . B Pi
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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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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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10. Appendix A: Animations 21 Conce
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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:
Page 642 and 643:
Figure 28: Battery 40 Concept 1: Pr
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Concept 3: 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 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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Page 698 and 699:
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
Page 708 and 709:
Figure 9: New Bumper Design - Half
Page 710 and 711:
Figure 10: Output Locations for NCA
Page 712 and 713:
B Pillar X-Velocity (mm/sec) . 4000
Page 714 and 715:
6. IIHS Response 17 Concept 3: Fina
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Toepan Right Intrusion (mm) A-B Pil
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Page 720 and 721:
Page 722 and 723:
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:
Page 736 and 737:
Figure 28: Battery 39 Concept 3: Fi
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Bumper Formability Milestone 19 Lig
Page 740 and 741:
Table of Contents 3 Bumper Formabil
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1. Objectives 5 Bumper Formability
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Page 746 and 747:
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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Page 754 and 755:
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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Page 766 and 767:
Page 768 and 769:
Abstract 2 IIHS DOE Response Surfac
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List of Figures 4 IIHS DOE Response
Page 772 and 773:
Figure 1: Bumper 6 IIHS DOE Respons
Page 774 and 775:
Outboard Rail Figure 3: LH Inner &
Page 776 and 777:
Page 778 and 779:
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
Page 788 and 789:
Rail Extension Rail Extension Reinf
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Page 792 and 793:
Page 794 and 795:
5. NCAP Response The figures below
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Page 798 and 799:
Page 800 and 801:
Page 802 and 803:
Abstract 2 Analysis of Vehicle With
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List of Figures 4 Analysis of Vehic
Page 806 and 807:
3. Modifications to Final Design 6
Page 808 and 809:
Figure 2: Front Cradle Mounts Figur
Page 810 and 811:
Figure 6: Rail Extension Welds A ma
Page 812 and 813:
Page 814 and 815:
5. NCAP Response 14 Analysis of Veh
Page 816 and 817:
vel (mm/sec) 4000 2000 -4000 -6000
Page 818 and 819:
Page 820 and 821:
Page 823 and 824:
Table of Contents Section Descripti
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List of Figures Number Title Page 1
Page 827 and 828:
List Of Photographs, Cont'd. Descri
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Purpose This 56 km/h (35 mph) front
Page 831 and 832:
Section 2.0 Impact Test Summary 2-1
Page 833 and 834:
Data Acquisition Explanations The p
Page 835 and 836:
Table 2 General Test and Vehicle Pa
Page 837 and 838:
Test vehicle's target test weight:
Page 839 and 840:
Table 3 Post-Impact Data Test type:
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Figure 2 Load Cell Barrier Configur
Page 843 and 844:
3 7 4 5 3 4 6 5 6 Figure 3 Vehicle
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Figure 4 Vehicle Crush Data Vehicle
Page 847 and 848:
Figure 5 Vehicle Intrusion Measurem
Page 849 and 850:
I L K J M Figure 7 Vehicle Intrusio
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Figure 9 Vehicle Toeboard Measureme
Page 853 and 854:
2 6 7 4 5 3 Figure 10 Camera Positi
Page 855 and 856:
Figure 11 Vehicle Reference Photo T
Page 857 and 858:
Figure A-1 Pre-Test Front View Figu
Page 859 and 860:
Figure A-5 Pre-Test Left Side View
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Figure A-9 Pre-Test Rear View Figur
Page 863 and 864:
Figure A-13 Pre-Test Right Side Vie
Page 865 and 866:
Figure A-17 Pre-Test Overhead View
Page 867 and 868:
Figure A-20 Pre-Test Front Underbod
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Figure A-24 Pre-Test Mid Underbody
Page 871 and 872:
Figure A-28 Pre-Test Rear Underbody
Page 873 and 874:
Figure A-32 Pre-Test Fuel Filler Ne
Page 875 and 876:
Figure A-35 Pre-Test Windshield Vie
Page 877 and 878:
Figure A-39 Pre-Test Right Front Wi
Page 940:
Appendix C Miscellaneous Test Instr
Page 945 and 946:
Frequency Response Classes SAE J211
Page 947 and 948:
Correlation of Vehicle With New Rai
Page 949 and 950:
Page 951 and 952:
3. NCAP Response Correlation of Veh
Page 953 and 954:
Page 955 and 956:
Page 957 and 958:
acc (g) acc (g) 50 40 30 20 10 0 50
Page 959 and 960:
force (N) 1.0E+06 9.0E+05 8.0E+05 7
Page 961 and 962:
Page 963 and 964:
Page 965 and 966:
Page 967 and 968:
Table of Contents Proteus Guideline
Page 969 and 970:
Table of Contents 1 Introduction...
Page 971 and 972:
1 Introduction Proteus Guidelines T
Page 973 and 974:
Powertrain Front-end Package of Pha
Page 975 and 976:
• LH and RH Pulse - NCAP B-pillar
Page 977 and 978:
7.1 Online Help Click on the Help o
Page 979 and 980:
Add or Delete an Architecture Click
Page 981 and 982:
7.4 Compute Response Scroll down th
Page 983 and 984:
DoE Parameters Click on the Paramet
Page 985 and 986:
Error Plots Click on the Error Grap
Page 987 and 988:
7.5 Load a Design from the Library
Page 989 and 990:
Deleting a User Design Click on the
Page 991 and 992:
7.8 Optimize Design Click on the Op
Page 993 and 994:
Figure 16: Proteus Optimizer Page
Page 995 and 996:
Initial Front-End Package: Phase I
Page 997 and 998:
Initial Front-End Package: Phase I
Page 999 and 1000:
1 18 17 4 5 Figure 1: Front-End Par
Page 1001 and 1002:
18 20 17 8 10 4 5 9 6 Figure 3: Fro
Page 1003 and 1004:
4/27 9/33 5/28 17/31 6/29 9/30 1/24
Page 1005 and 1006:
Normalized Grade -13.8 -12.7 700 MP
Page 1007 and 1008:
Table of Contents 1 Front-End DoE P
Page 1009 and 1010:
34 Panel Body Side Outer Top & B-Pi
Page 1011 and 1012:
19 21 17 6 4 18 5 16 9 Figure 1: Fr
Page 1013 and 1014:
S.N. 1 2 Table 4: Topological Param
Page 1015 and 1016:
Normalized Grade 500 MPa 2 1 Overal
Page 1017 and 1018:
4 IIHS Study of Upgraded Front-End
Page 1019 and 1020:
18/39 4/27 17/ 38 21/42 5/28 6/29 2
Page 1021 and 1022:
Stamped Design: Phase II Lightweigh
Page 1023 and 1024:
1 DOE Parts Rail Front Inner/Outer
Page 1025 and 1026:
3 NCAP/IIHS Studies The NCAP/IIHS D
Page 1027 and 1028:
4 References 1) DOE FE Models, Mile
Page 1029 and 1030:
Abstract 2 Static Dynamic Stiffness
Page 1031 and 1032:
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
Page 1039 and 1040:
Figure 1: Bumper Figure 2: LH Rail
Page 1041 and 1042:
Rail Extension 3. Model Modificatio
Page 1043 and 1044:
Figure 6: Final Concept 2 Design BI
Page 1045 and 1046:
Corrected Theta in degrees Correcte
Page 1047 and 1048:
Dynamic Stiffness DOE Response Surf
Page 1049 and 1050:
Table of Contents 3 Dynamic Stiffne
Page 1051 and 1052:
Figure 1: Bumper Figure 2: LH Rail
Page 1053 and 1054:
Rail Extension 3. Model Modificatio
Page 1055 and 1056:
Figure 6: Final Concept 2 Design BI
Page 1057:
5. Conclusions 11 Dynamic Stiffness
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Auto/Steel Partnership - American Iron and Steel Institute

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