Highly Engineered Structural Solutions for the 21 st Century Autobody

Transcription

1 Highly Engineered Structural Solutions for the 21 st Century Autobody Steven W. Jansen content contributed by T. Vikstrom, P. McKune, K. Palanisamy, R. Kozak Noble Advanced Technologies A Noble International Company

2 Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars

3 P-Tech Process Pullman Industries tubular steel hot-forming process introduced on 2005 Ford Mustang 1 Tubular blank is roll formed using 450 Mpa Boron steel 2 Tubular blank is heated to 1700 F for maximum formability 3 Hot blank is formed then quenched inside press Result Tensile: ~ 1500 Mpa True Plastic Strain: 25-40%

4 P-Tech Process P-Tech Bumper Ford Mustang Bumpers Thickness: 1.28 mm Highly swept UHSS bumpers Detailed and variable cross sections tune product for maximum efficiency 30% weight savings over traditional UHSS B sections are comparable to weights of aluminum beams Length: Weight: 1100/1405 mm 4.5/5.9 kg

5 P-Tech Process P-Tech Roof Bow General Roll-forming can provide multiple parts with unique sweeps and lengths when a common section is maintained Very thin walls achievable Lower mass by up to 30% One piece closed sections Increased structural stiffness Lower cost Center Roof Bow Thickness: 0.5 mm Length: 1000 mm Weight: 0.8 kg

6 Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars

7 Technology Merge Noble Pullman Cowl Sides Crush Tubes Sunroof Rings Bodyside Inners Longitudinal Rails Wheelhouse Inners Liftgate Inners Frame Rails Side Sills Fender Inners Pillars Bumpers Door Inners Rocker Reinforcements Door Intrusion Beams Cross Car Beams Crossmembers Door Frames Roof Bows Load Floors Glass Channels Door Tracks Window Guides Windshield Headers Seat & Backframe Components Front of Dash Panel Drip Rails Seal Retainers

8 Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars

9 Highly Engineered Bumper Systems FEA Model Centerline (C/L) Load Case Bumper System 38.8 mm Overlap IIHS Curved Barrier

10 Exploded FEA Model Highly Engineered Bumper Systems Crush Can Mounting Plate Bumper Beam

11 P-tech 1.55mm Mass: 4.86 kg Highly Engineered Bumper Systems 1.55 mm gage C/L Section Bumper Beam

12 Highly Engineered Bumper Systems New Technology top /1.2mm bottom Mass: kg 1.7 mm gage C/L Section Bumper Beam 1.2 mm gage

13 Laser Welded 1.7/1.2 mm vs mm Highly Engineered Bumper Systems

14 Highly Engineered Bumper Systems Conclusions Compared to baseline single-gage proposals, the ratio between performance and mass savings for a downgaged single-gage proposal is similar to that of a dual-gage proposal. EXCEPTION: For this case study, 1.7 mm top/1.2 mm bottom dual-gage proposal delivers performance comparable to that of 1.55 mm single-gage proposal at Kg lower mass for C/L Barrier load case Laser Welded Proposal Provides a 14% Mass Savings

15 Laser Welded 2 : 2.0 mm 80 Ksi Mass: Kg Highly Engineered Bumper Systems 2.0 mm Thick, 80 Ksi Material C/L Section Bumper Beam

16 Highly Engineered Bumper Systems Laser Welded 2 : 2.0 mm 80 Ksi (TOP), and 1.2 mm M190 (BOTTOM) Mass: Kg 2.0 mm Thick, 80 Ksi Material 1.2 mm Thick, M190 Material C/L Section Bumper Beam

17 Highly Engineered Bumper Systems

18 Results Summary Highly Engineered Bumper Systems S. No. Bumper System 10 Kmh C/L Curved Barrier Impact Force(KN) Disp(mm) 1 Baseline: Uniform 2.0 mm thick, 80 Ksi Bumper Beam Laser Welded Proposal 2: 2.0 mm 80 Ksi(TOP), and 1.2 mm M190(BOTTOM) Bumper Beam S. No. Bumper System Mass (Kg) % Mass Saving 1 Baseline: Uniform 2.0 mm thick, 80 Ksi Bumper Beam Laser Welded Proposal 2: 2.0 mm 80 Ksi(TOP), and 1.2 mm M190(BOTTOM) Bumper Beam %

19 Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars

20 Door Intrusion Beams Simulation Study Study Purpose To evaluate the performance of Industry Leading Hot Formed Hat Section Door Beam under increased requirements To evaluate circular and square cross section door beams To demonstrate capabilities of New Technology Door Beams

21 Door Intrusion Beams Simulation Study Industry Leading Section Animation through 6 Intrusion

22 Door Intrusion Beams Simulation Study Constant Circular Section Animation through 6 Intrusion

23 Door Intrusion Beams Simulation Study New Tech Section Animation through 6 Intrusion

24 Results Summary 6 Intrusion Event Door Intrusion Beams Simulation Study Door Beam Thickness (mm) Mass (Kg) Energy till 6" (J) Specific Energy till 6 (J/Kg) Industry Leading Hot Form Section Constant closed circular section New Tech

25 Results Summary 12 Intrusion Event Door Intrusion Beams Simulation Study Door Beam Thickness (mm) Mass (Kg) Energy till 12" (J) Specific Energy till 12 (J/Kg) Industry Leading Hot Form Section ,189 4,886 Constant Closed Circular Section ,011 4,826 New Tech ,274 6,141

26 Conclusions New Tech Side Impact Beam outperforms the Industry Leading Hot Formed Door Beam Specific Energy (J/kg) is 7% greater than baseline for New Tech Beam at 6 intrusion and 26% greater at 12 intrusion New Tech Door Beam is the Most Efficient New Tech is ready to accept more stringent side impact requirements with no mass gain Door Intrusion Beams Simulation Study

27 Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars

28 Safety Engineered B-Pillars 1. Boron Steel Flat Blank 2. Laser Seam Welded Multi-diameter Tubes 3. Heat Treatment 4. Forming 5. Quenching 6. Tubular UHSS New Tech B-Pillar Combines ultra high strength steel (UHSS) with multi-diameter tubular geometry to create the ultimate safety component for roof crush and side impact performance.

29 Safety Engineered B-Pillars Iso View Sub-assembled to BP Inner + Adhesive Baseline B-Pillar 1.6 mm HS350, 4.54 kg New Tech B-Pillar, Rear View 1.4 mm Boron, 3.82 kg Side View Behind Body Side Outer

30 Safety Engineered B-Pillars IIHS Side Impact Performance 1.6 mm HS350 Baseline 1.4 mm New Tech BP A 1.4 mm Boron Baseline B 1.6 mm Boron Baseline C 1.6 mm HS350 Baseline D 1.4 mm New Tech BP mm mm

31 Safety Engineered B-Pillars 1.6 mm HS350 Baseline Roof Crush Performance 1.4 mm New Tech Tube 1.4 mm Boron Baseline 1.6 mm Boron Baseline 1.6 mm HS350 Baseline 1.4 mm New Tech BP Displacement (inches) A 1.4 mm Boron Baseline B 1.6 mm Boron Baseline C 1.6 mm HS350 Baseline D 1.4 mm New Tech BP

32 Safety Engineered B-Pillars Results Summary Advantages of New Tech B-Pillar Equivalent Side Impact Performance to 1.6 mm Hot Stamped B-Pillar 31% more roof crush GVW resisted than 1.6 mm Hot Stamped B-Pillar 1.44 kg (3.2 lb) weight reduction versus 1.6 mm Hot Stamped B-Pillar 16% weight savings versus 1.6 mm Baseline and Hot Stamped B-Pillar Reduced tooling cost versus Hot Stamped B-Pillar