Auto/Steel Partnership - American Iron and Steel Institute

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Concept 1: DOE Figure 4-6 show the normalized Sum of Squares (7) for crush, and LH B-pillar acceleration pulse. The DOE study showed that gauges had a more significant effect on the NCAP performance than grades. Out of the top 9 factors that affect the acceleration between 40-70ms (Figure 6), 4 were gauges and only 2 were grades. Furthermore, the mid rail gauge was the dominant factor affecting the B-pillar pulse. The initial peak was affected more by rail as compared to bumper (Figure 5). This scenario is quite different from the Phase I DOE studies (8) in which the bumper dictated the initial peak. The dominant effect of gauges suggests that the design lacks geometric stability. Hence, the full potential of high strength materials is not realized as the rails do not crush well axially. Normalised SS 60 50 40 30 20 10 0 (rail mid t) (bumper t) Crush : Top 9 Factors/Interactions (rail mid mat) (rail ext t) (bumper t) x(rail mid t) (bumper t) x(rail front t) 9 (rail ext mat) (bumper mat) x (rail mid t) Figure 4: Crush Response: Top 9 Factors / Interactions (rail front t) Auto/Steel Partnership
Normalized SS Normalized SS 35 30 25 20 15 10 5 0 (rail front t) 50 45 40 35 30 25 20 15 10 5 0 (rail mid t) 0-10 ms Acc (LH) : Top 9 Factors/Interactions (rail mid t) (bumper t) x (rail front t) (bumper t) x (bumper mat) (rail front t) x (rail mid t) 10 (rail mid mat) (bumper t) (bumper mat) x (rail front t) Figure 5: Peak Acceleration in 0-10ms: Top 9 Factors / Interactions 40-70ms Acc (LH):Top Factors/Interactions (rail ext t) (bumper t) (bumper t) x (rail mid t) (bumper t) x (bumper mat) (rail ext mat) (rail front t) (bumper t) x (rail front t) Figure 6: Peak Acceleration in 40-70ms: Top 9 Factors / Interactions Concept 1: DOE (bumper mat) (bumper mat) 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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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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Page 484 and 485: Concept 1 Subsystem Design The subs
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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
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Page 516 and 517: Concept 1: Preliminary Design modpl
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Page 520 and 521: Concept 1: Preliminary Design accl.
Page 522 and 523: Concept 1: DOE Study Milestone 11 L
Page 524 and 525: Table of Contents 3 Concept 1: DOE
Page 526 and 527: 1. Objectives 5 Concept 1: DOE The
Page 528 and 529: 4. FE Model - Output Location Summa
Page 532 and 533: 6. Conclusions 11 Concept 1: DOE An
Page 534 and 535: 9. Appendix A: Concept1 Baseline FE
Page 536 and 537: Concept 1: DOE MTG1 60412 SectShll1
Page 538 and 539: Concept 1: DOE can2 61105 90060010
Page 540 and 541: Concept 1: DOE bintongue 61208 9006
Page 542 and 543: Concept 1: DOE fbhplrrnf1.l 61623 S
Page 544 and 545: 23 Concept 1: DOE SpotWelds 62039 N
Page 546 and 547: Abstract 2 Concept 1: Final Design
Page 548 and 549: List of Figures 4 Concept 1: Final
Page 550 and 551: Concept 1: Final Design The Final D
Page 552 and 553: Part Baseline Design Table 5: Grade
Page 554 and 555: Figure 2: Output Locations for NCAP
Page 556 and 557: B Pillar X-Acceleration (g) . B Pil
Page 558 and 559: 6. IIHS Response IIHS intrusions ar
Page 560 and 561: 7. Conclusions 16 Concept 1: Final
Page 562 and 563: 10. Appendix A: Animations 18 Conce
Page 564 and 565: Concept 1: Final Design Component N
Page 574 and 575: Concept 2: Preliminary Design Miles
Page 576 and 577: Table of Contents 3 Concept 2: Prel
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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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6. IIHS Response IIHS intrusions ar
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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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4. FE Model - Output Location Summa
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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:
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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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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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6. IIHS Response IIHS intrusions ar
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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
Page 1007 and 1008:
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
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
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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
Page 1027 and 1028:
4 References 1) DOE FE Models, Mile
Page 1029 and 1030:
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
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
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Figure 1: Bumper Figure 2: LH Rail
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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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