Auto/Steel Partnership - American Iron and Steel Institute

More documents

Recommendations

Info

3. Modifications to Final Design 6 Analysis of Vehicle With New Rail System The following changes were made in the Final Design, to reflect all modifications made during manufacturing and assembly, and to account for events observed in the NCAP test. 1. Take up beads were added to the rail extension reinforcement to allow for easier fabricating (Figure 1). 2. Tooling holes were added to the rail components. 3. Some minor manufacturing related cross-sectional changes were also updated. 4. Front cradle front mounts (inner/outer) were modified (Figure 2). � Parts were not fabricated by stamping; they were hand-fabricated and seam welded in places. � The design was changed slightly to remove the bump on the side near the rail attachment flanges. � CAD data was not available; hence FE model was updated using measured dimensions. � A gauge of 2.5mm was used, instead of the design gauge of 1.95mm, due to availability of sheet metal. 5. Tie bar bracket was re-designed during assembly and is thus different from the original tie bar bracket (Figure 3). � Tie bar bracket was seam welded to the rail. 6. The front wheelhouse panel was redesigned (Figure 4). 7. The battery tray support bracket was modified, as its design is different in the Donor vehicle than the FE model (Figure 5). The FE model has a stamped design, where the actual vehicle has a bent tubular design. 8. The following changes were made to the LH engine mount. � Material was changed from aluminum to steel. � Gauge was changed from 8mm to 3mm. � Mount failure option was removed, as the mount did not fail in test. Instead, the spotwelds between the LH engine mount and the cradle were failed at 22ms, as they were found to have failed in the NCAP test vehicle. The failure time was taken as the time at which the LH test pulse dropped almost to zero (Ref. 15). This failure is only applicable to NCAP simulation and should not be used for IIHS simulation. 9. The spring representing the front cradle mount bolt connection to rails was removed as the bolt failed in the NCAP test. This failure is only applicable to NCAP simulation and should not be used for IIHS simulation. 10. Front bumper hole locations were repositioned slightly. 11. Weld pattern in the rail extension welds to the floor and dash was modified, due to drilling out of donor vehicle welds and puddle welding to the rail extension. In addition, a few welds between the rail extension and the dash were removed, as the test vehicle did not have them (Figure 6). Auto/Steel Partnership
Analysis of Vehicle With New Rail System 12. There is one less weld at the back of the lower flange on the front rail inner and outer due to the addition of a chamfer. 13. Structural adhesive was used on the lower flange of the front rail inner and outer between the front cradle mount, rather than welding. This was necessary due to lack of access for the weld gun in this area, due to the order of assembly. The adhesive was represented by a continuous rigid connection. 14. The front hood bolts were failed at 32ms, as observed in the test vehicle. The bolts in the test vehicle were 6mm in diameter, instead of the 8mm diameter bolts in the production vehicle. This failure is only applicable to NCAP simulation and should not be used for IIHS simulation. The following modifications could not be made to the FE model: � The geometry of the engine mounts in the CAD/FE data is different from that of the actual mounts in the test vehicle. Consequently, the engine mount models could not be updated. � An extra bracket on the side of the front cradle mount was not modeled as it was a non-structural part and no CAD data was available. Figure 1: Rail Extension Reinforcement 7 Auto/Steel Partnership
Page 1 and 2:
Auto/Steel Partnership
Page 3 and 4:
Contents Introduction..............
Page 5 and 6:
Formability .......................
Page 7 and 8:
LIGHTWEIGHT FRONT END STRUCTURE Pha
Page 9 and 10:
Structural Performance Targets [3]
Page 11 and 12:
Formability Requirements [8] LIGHTW
Page 13 and 14:
Design Space LIGHTWEIGHT FRONT END
Page 15 and 16:
Page 17 and 18:
Page 19 and 20:
Page 21 and 22:
Initial Front End Package LIGHTWEIG
Page 23 and 24:
Page 25 and 26:
Upgraded Front End Package LIGHTWEI
Page 27 and 28:
Figure 2.4: Topological Changes to
Page 29 and 30:
Page 31 and 32:
Page 33 and 34:
Page 35 and 36:
Seat/floor panel peak acceleration
Page 37 and 38:
HIC Chest peak acceleration (g) 100
Page 39 and 40:
Structural Targets LIGHTWEIGHT FRON
Page 41 and 42:
Page 43 and 44:
Bumper Design LIGHTWEIGHT FRONT END
Page 45 and 46:
umper rail joint. Case Bumper Beam
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Page 53 and 54:
Page 55 and 56:
B- Pillar Acceleration (g) 30.0 25.
Page 57 and 58:
Page 59 and 60:
X - Acceleration (g) 35.00 30.00 25
Page 61 and 62:
Page 63 and 64:
35 30 25 20 15 10 5 0 -5 Figure 4.1
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Parametric Study / LIGHTWEIGHT FRON
Page 73 and 74:
Results Summary LIGHTWEIGHT FRONT E
Page 75 and 76:
Page 77 and 78:
* Baseline values Parameters D.O.E.
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
Page 85 and 86:
Page 87 and 88:
Page 89 and 90:
* Baseline values LIGHTWEIGHT FRONT
Page 91 and 92:
NCAP Parametric Study LIGHTWEIGHT F
Page 93 and 94:
Page 95 and 96:
acc (g) 50 40 30 20 10 0 Max B-Pill
Page 97 and 98:
Normalized Grade Normalized Grade 7
Page 99 and 100:
Design Variables: Acceleration
Page 101 and 102:
Page 103 and 104:
Page 105 and 106:
X-Acceleration (g) 35 30 25 20 15 1
Page 107 and 108:
Page 109 and 110:
Stiffness (N/m) Stiffness (N/m) 60.
Page 111 and 112:
Page 113 and 114:
Page 115 and 116:
Page 117 and 118:
Normalized SS Normalized SS 50 45 4
Page 119 and 120:
Normalized Grade Normalized Grade 5
Page 121 and 122:
Page 123 and 124:
Intrusion (cm) Intrusion (cm) 30.0
Page 125 and 126:
Intrusion (cm) Intrusion (cm) 30 25
Page 127 and 128:
Page 129 and 130:
Performance Matrix Computer Aided L
Page 131 and 132:
References 1) Phase I Structural Pe
Page 133 and 134:
Intrusion (cm) X-Acceleration (g) 4
Page 135 and 136:
Design Design Mass Saving (Kg) 0 -
Page 137 and 138:
X-Accel (g) 30 25 20 15 10 5 0 LIGH
Page 139 and 140:
Optimal Design 7 LIGHTWEIGHT FRONT
Page 141 and 142:
S. No Part Name LIGHTWEIGHT FRONT E
Page 143 and 144:
X-Accel (g) 40 35 30 25 20 15 10 5
Page 145 and 146:
Design Design Mass Delta (Kg) Mass
Page 147 and 148:
S. No. Part Name Part ID LH Part ID
Page 149 and 150:
Description Torsional Stiffness (N-
Page 151 and 152:
Page 153 and 154:
X-Accel 35 30 25 20 15 10 5 0 LIGHT
Page 155 and 156:
S. No Part Name DOE Baseline LIGHTW
Page 157 and 158:
References 1) Phase I Structural Pe
Page 159 and 160:
Page 161 and 162:
Figure 8.2: Drawbeads Location Figu
Page 163 and 164:
Figure 8.7: Formability - Dash Pane
Page 165 and 166:
Figure 8.11: Formability - Rocker I
Page 167 and 168:
Page 169 and 170:
Figure 8.18: Formability - Rail Inn
Page 171 and 172:
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
Page 179 and 180:
Page 181 and 182:
Page 183 and 184:
Page 185 and 186:
Page 187 and 188:
Page 189 and 190:
Figure 8.47: Minor Strain Figure 8.
Page 191 and 192:
Page 193 and 194:
Figure 8.56: Front Rail Inner - Maj
Page 195 and 196:
Simulation Results Figure 8.60: Fro
Page 197 and 198:
Page 199 and 200:
Page 201 and 202:
Cost Model LIGHTWEIGHT FRONT END ST
Page 203 and 204:
Page 205 and 206:
Knowledge Base LIGHTWEIGHT FRONT EN
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
Page 217:
Page 220 and 221:
Table of Contents 3 Lightweight Fro
Page 222 and 223:
List of Tables 5 Lightweight Front
Page 224 and 225:
4. Results Summary 7 Lightweight Fr
Page 226 and 227:
Table 2: Grade and Gauge Summary of
Page 228 and 229:
FE Model Validation (4), (5), (6) 1
Page 230 and 231:
6. Rail Concept Development Three r
Page 232 and 233:
Best Hydroformed Design The Hydrofo
Page 234 and 235:
Best Stamped Design The Stamped Des
Page 236 and 237:
Figure 11: Bumper Assembly 19 Light
Page 238 and 239:
Figure 14: Stamped Rail and Attache
Page 240 and 241:
23 Lightweight Front End Structure
Page 242 and 243:
B Pillar X-Acceleration (g) . 40 35
Page 244 and 245:
8. Knowledge Base 27 Lightweight Fr
Page 246 and 247:
9. Manufacturing 29 Lightweight Fro
Page 248 and 249:
Thinning < 10% : Design Feasible 31
Page 250 and 251:
Original Prototyping Processes Fina
Page 252 and 253:
Figure 22: Front Rail Inner/Outer F
Page 254 and 255:
Figure 26: Bumper Assembly 37 Light
Page 256 and 257:
Dimensional Tolerance Analyses 39 L
Page 258 and 259:
Figure 32: Bumper Tolerances 41 Lig
Page 260 and 261:
Figure 34: Weld Fixtures Figure 35:
Page 262 and 263:
Figure 37: NCAP Test - Front View F
Page 264 and 265:
Figure 41: NCAP Test - Bumper Close
Page 266 and 267:
12. Conclusions 49 Lightweight Fron
Page 268 and 269:
14. Appendix A: FE Model Model mass
Page 270 and 271:
15. Appendix B: Milestone Reports 1
Page 272 and 273:
16. Appendix C: A/SP Reports A/SP E
Page 274 and 275:
Abstract 2 Competitive Benchmarking
Page 276 and 277:
List of Figures 4 Competitive Bench
Page 278 and 279:
6 Competitive Benchmarking Rigid Fi
Page 280 and 281:
8 Competitive Benchmarking The foll
Page 282 and 283:
Figure 5: Rail Deformations at 0ms:
Page 284 and 285:
Figure 9: Rail Deformations at 40ms
Page 286 and 287:
3.1. Design 0 This design served as
Page 288 and 289:
4. Subsystem Comparison 16 Competit
Page 290 and 291:
Competitive Benchmarking Figure 16:
Page 292 and 293:
5. Conclusions 20 Competitive Bench
Page 294 and 295:
8. Appendix A: Animations 22 Prelim
Page 296 and 297:
Abstract 2 Competitive Benchmarking
Page 298 and 299:
Competitive Benchmarking List of Fi
Page 300 and 301:
1. Objectives 6 Competitive Benchma
Page 302 and 303:
Model/Make Front Rail Cross- Table
Page 304 and 305:
2002 Honda Accord � Straight rail
Page 306 and 307:
2003 Toyota Corolla 4 Dr Sedan �
Page 308 and 309:
5. Conclusions The following design
Page 310 and 311:
Competitive Benchmarking 8. Appendi
Page 312 and 313:
2001 VW Golf Figure 11: VW Golf - R
Page 314 and 315:
Figure 13: VW Golf - Front Rails (i
Page 316 and 317:
2002 VW Passat Figure 15: VW Passat
Page 318 and 319:
2001 Mercedes Benz S-500 24 Competi
Page 320 and 321:
Figure 19: Mercedes Benz S-500 - Fi
Page 322 and 323:
Figure 22: Honda Accord - Front Rai
Page 324 and 325:
2002 Honda Civic Figure 24: Honda C
Page 326 and 327:
Figure 27: Honda Civic - Front Rail
Page 328 and 329:
2003 Honda Pilot Figure 29: Honda P
Page 330 and 331:
Figure 33: Lexus LS430 - First Cros
Page 332 and 333:
Front Rail Rear Rail Front Rail Fig
Page 334 and 335:
Figure 39: Toyota Camry - Bumper Cr
Page 336 and 337:
2003 Saturn Ion Figure 42 LH front
Page 338 and 339:
2002 Saturn VUE Figure 45: LH front
Page 340 and 341:
2002 Lincoln LS Figure 49: Lincoln
Page 342 and 343:
Abstract 2 Rail Concept Development
Page 344 and 345:
List of Figures 4 Rail Concept Deve
Page 346 and 347:
3. Existing Rail Architecture 6 Rai
Page 348 and 349:
Figure 3: LH Rail Assembly 8 Rail C
Page 350 and 351:
Figure 5: Bumper Assembly 10 Rail C
Page 352 and 353:
Rail Concept Development European p
Page 354 and 355:
Rail Concept Development sweep, wid
Page 356 and 357:
4. Best Stamped Design 16 Rail Conc
Page 358 and 359:
Rail Concept Development The rail c
Page 360 and 361:
Figure 14: Additional Reinforcement
Page 362 and 363:
Rail Concept Development Phase I st
Page 364 and 365:
5. Best Hydroformed Design 24 Rail
Page 366 and 367:
Figure 20: LH Rail - Plan View 26 R
Page 368 and 369:
7. Conclusions 28 Rail Concept Deve
Page 370 and 371:
Validated FE Models Milestone 5 Lig
Page 372 and 373:
Table of Contents 3 Validated FE Mo
Page 374 and 375:
1. Objectives 5 Validated FE Models
Page 376 and 377:
Figure 1: NCAP Full Vehicle FE Mode
Page 378 and 379:
4. NCAP Response Figure 4: Deformat
Page 380 and 381:
B Pillar X-Acceleration (g) . B Pil
Page 382 and 383:
B Pillar X-Velocity (mm/sec) . B Pi
Page 384 and 385:
5. IIHS Response Figure 14: Deforma
Page 386 and 387:
Figure 17: Deformation of Front End
Page 388 and 389:
8. Appendix A: Animations 19 Valida
Page 390 and 391:
Component Name ID Property Name ID
Page 392 and 393:
23 Validated FE Models tir2.l 71113
Page 394 and 395:
25 Validated FE Models trqbox1.r 11
Page 396 and 397:
27 Validated FE Models ailctr2.l 12
Page 398 and 399:
29 Validated FE Models foam 9006002
Page 400 and 401:
31 Validated FE Models tipof bin 90
Page 402 and 403:
Abstract 2 Enhanced FE Models This
Page 404 and 405:
List of Figures 4 Enhanced FE Model
Page 406 and 407:
3. Model Modifications 6 Enhanced F
Page 408 and 409:
Figure 4: IP Coarse Mesh Model Figu
Page 410 and 411:
Figure 8: Windshield Coarse Mesh Mo
Page 412 and 413:
Figure 11: NCAP Full Vehicle FE Mod
Page 414 and 415:
Page 416 and 417:
Page 418 and 419:
Table 5: NCAP Crash Events Time (ms
Page 420 and 421:
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 454 and 455:
Page 456 and 457:
Page 458 and 459:
DOE FE Models Table 6: NCAP Crash E
Page 460 and 461:
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 468 and 469:
DOE FE Models MTG1 60412 SectShll10
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:
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
Page 518 and 519:
Concept 1: Preliminary Design drlwh
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:
Page 530 and 531:
Concept 1: DOE Figure 4-6 show the
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:
Page 556 and 557:
Page 558 and 559:
Page 560 and 561:
7. Conclusions 16 Concept 1: Final
Page 562 and 563:
Page 564 and 565:
Concept 1: Final Design Component N
Page 566 and 567:
Page 568 and 569:
Page 570 and 571:
Page 572 and 573:
Page 574 and 575:
Page 576 and 577:
Page 578 and 579:
Page 580 and 581:
Figure 2: LH Inner & Outer Rails 7
Page 582 and 583:
Figure 4: LH Skirt Reinforcement 9
Page 584 and 585:
Figure 6: New Bumper Design - Close
Page 586 and 587:
13 Concept 2: Preliminary Design Ta
Page 588 and 589:
Page 590 and 591:
Page 592 and 593:
Page 594 and 595:
Page 596 and 597:
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:
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:
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
Page 632 and 633:
Concept 1: Preliminary Design fdrbd
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 644 and 645:
Page 646 and 647:
Page 648 and 649:
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:
Page 666 and 667:
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:
Page 694 and 695:
Norm SS 30 25 20 Norm SS 15 10 5 0
Page 696 and 697:
Page 698 and 699:
Concept 3: Final Design Milestone 1
Page 700 and 701:
Table of Contents 3 Concept 3: Fina
Page 702 and 703:
1. Objectives 5 Concept 3: Final De
Page 704 and 705:
Figure 3: LH Rail - Isometric View
Page 706 and 707:
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
Page 716 and 717:
Toepan Right Intrusion (mm) A-B Pil
Page 718 and 719:
Page 720 and 721:
Page 722 and 723:
25 Concept 3: Final Design tiebar4.
Page 724 and 725:
27 Concept 3: Final Design ai_icebo
Page 726 and 727:
29 Concept 3: Final Design part.15
Page 728 and 729:
31 Concept 3: Final Design rrhdr 61
Page 730 and 731:
12. Appendix C: Attached Parts Figu
Page 732 and 733:
Figure 24: Front Cradle Mount 35 Co
Page 734 and 735:
Figure 26: Torque Box 37 Concept 3:
Page 736 and 737:
Figure 28: Battery 39 Concept 3: Fi
Page 738 and 739:
Bumper Formability Milestone 19 Lig
Page 740 and 741:
Table of Contents 3 Bumper Formabil
Page 742 and 743:
1. Objectives 5 Bumper Formability
Page 744 and 745:
Figure 2: New Bumper Design - Close
Page 746 and 747:
4. Bumper Formability Results 9 Bum
Page 748 and 749:
Target Thinning
Page 750 and 751:
Figure 7: Bumper Outer - FLD Curve
Page 752 and 753:
Page 754 and 755:
NCAP DOE Response Surface Milestone
Page 756 and 757: Table of Contents 3 NCAP DOE Respon
Page 758 and 759: 1. Objectives 5 NCAP DOE Response S
Page 760 and 761: Figure 2: LH Rail Assembly 7 NCAP D
Page 762 and 763: Rail Extension 3. NCAP Response Sur
Page 764 and 765: Figure 5: Output Locations for NCAP
Page 766 and 767: 7. References 1) Validated FE Model
Page 768 and 769: Abstract 2 IIHS DOE Response Surfac
Page 770 and 771: 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: 4. FE Model - Output Location Summa
Page 778 and 779: 5. Conclusions 12 IIHS DOE Response
Page 780 and 781: Final Optimized Design Milestone 22
Page 782 and 783: Table of Contents 3 Final Optimized
Page 784 and 785: 1. Objectives 5 Final Optimized Des
Page 786 and 787: Table 3: Static Stiffness Results 7
Page 788 and 789: Rail Extension Rail Extension Reinf
Page 790 and 791: Figure 5: New Bumper Design - Close
Page 794 and 795: 5. NCAP Response The figures below
Page 796 and 797: 6. IIHS Response IIHS intrusions ar
Page 800 and 801: 11. Appendix B: Summary of FE Model
Page 802 and 803: Abstract 2 Analysis of Vehicle With
Page 804 and 805: List of Figures 4 Analysis of Vehic
Page 808 and 809: Figure 2: Front Cradle Mounts Figur
Page 810 and 811: Figure 6: Rail Extension Welds A ma
Page 814 and 815: 5. NCAP Response 14 Analysis of Veh
Page 816 and 817: vel (mm/sec) 4000 2000 -4000 -6000
Page 820 and 821: 10. Appendix B: Summary of FE Model
Page 823 and 824: Table of Contents Section Descripti
Page 825 and 826: List of Figures Number Title Page 1
Page 827 and 828: List Of Photographs, Cont'd. Descri
Page 829 and 830: 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:
Page 841 and 842: Figure 2 Load Cell Barrier Configur
Page 843 and 844: 3 7 4 5 3 4 6 5 6 Figure 3 Vehicle
Page 845 and 846: 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
Page 851 and 852: 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
Page 861 and 862:
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
Page 869 and 870:
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
show all

Auto/Steel Partnership - American Iron and Steel Institute

Create successful ePaper yourself

Delete template?

Save as template?