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Concept 3: Preliminary Design Milestone 16 Lightweight Front End Structure Phase II September 10, 2003 Auto/Steel Partnership
Abstract 2 Concept 1: Preliminary Design This report documents the preliminary design for Concept 3 that has a new hydroformed rail design and a stamped bumper design. A final design for Concept 3 will be obtained, based on a DOE study. The final Concept 3 design will be compared to Concepts 1 and 2 developed in Phase II of the Lightweight Front End Structure Project. 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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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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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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Page 594 and 595: 9. References 1) Validated FE Model
Page 596 and 597: 11. Appendix B: Summary of FE Model
Page 598 and 599: Abstract 2 Concept 1: Preliminary D
Page 600 and 601: List of Figures 4 Concept 1: Prelim
Page 602 and 603: 3. DOE Responses 6 Concept 1: Preli
Page 604 and 605: Concept 2: Final Design Milestone 1
Page 606 and 607: Table of Contents 3 Concept 2: Fina
Page 608 and 609: 1. Objectives 5 Concept 2: Final De
Page 610 and 611: Outboard Rail Figure 2: LH Inner &
Page 612 and 613: Figure 4: New Bumper Design 9 Conce
Page 614 and 615: Figure 6: Bumper Attachment 11 Conc
Page 616 and 617: 4. FE Model - Output Location Summa
Page 618 and 619: The figures below summarize the NCA
Page 620 and 621: Concept 2: Final Design Table 6: NC
Page 622 and 623: 7. Conclusions 19 Concept 2: Final
Page 624 and 625: 10. Appendix A: Animations 21 Conce
Page 626 and 627: Concept 1: Preliminary Design lcarn
Page 628 and 629: Concept 1: Preliminary Design tire1
Page 630 and 631: Concept 1: Preliminary Design pivot
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Page 634 and 635: Concept 1: Preliminary Design rbmpb
Page 636 and 637: 12. Appendix C: Attached Parts Figu
Page 638 and 639: Figure 24: Front Cradle Mount 36 Co
Page 640 and 641: Figure 26: Torque Box 38 Concept 1:
Page 642 and 643: Figure 28: Battery 40 Concept 1: Pr
Page 646 and 647: Table of Contents 3 Concept 1: Prel
Page 648 and 649: 1. Objectives 5 Concept 1: Prelimin
Page 650 and 651: Figure 3: LH Rail - Isometric View
Page 652 and 653: Concept 1: Preliminary Design The r
Page 654 and 655: Figure 9: New Bumper Design - Half
Page 656 and 657: Figure 10: Output Locations for NCA
Page 658 and 659: B Pillar X-Velocity (mm/sec) . 4000
Page 660 and 661: 6. IIHS Response 17 Concept 1: Prel
Page 662 and 663: Toepan Right Intrusion (mm) A-B Pil
Page 664 and 665: 9. References 1) Validated FE Model
Page 666 and 667: 11. Appendix B: Summary of FE Model
Page 668 and 669: Concept 1: Preliminary Design tieba
Page 670 and 671: Concept 1: Preliminary Design upper
Page 672 and 673: Concept 1: Preliminary Design outer
Page 674 and 675: Concept 1: Preliminary Design gusse
Page 676 and 677: Concept 1: Preliminary Design out_r
Page 678 and 679: Figure 22: Attached Parts - Side Vi
Page 680 and 681: Figure 25: Suspension Panel 37 Conc
Page 682 and 683: Figure 27: Rear Cradle Mount 39 Con
Page 684 and 685: Figure 29: Tie Bar 41 Concept 1: Pr
Page 686 and 687: Abstract 2 Concept 3: DOE This repo
Page 688 and 689: List of Figures 4 Concept 3: DOE Fi
Page 690 and 691: 3. DOE Model 6 Concept 3: DOE The D
Page 692 and 693: Figure 2: Output Locations for NCAP
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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
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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