A Winner: Car Body Design Development of the Hyundai Sonata

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1 A Winner: Car Body Design Development of the Hyundai Sonata Carsten Höfer Hyundai Motor Europe Technical Center w w w. a u t o s t e e l. o r g

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3 Product Concept / Product Concept Background History Background Customer History proposition Styling Customer proposition Practicality Styling Performance Practicality Efficiency Efficiency BiW Concept Development process Platform Development strategy process Weight optimization Stiffness Material Safety Safety Overview of Ulsan Plant Manufacturing strategy Flexible production system Productivity Quality

4 i40 intro.m4v

5 Product Concept

6 Product Concept

7 2010 Sedan 2011 Sedan & Wagon Product Concept

8 Best in class roominess Class leading practicality Best in class with 113g CO2/km 3 USPs: rear seat reclining, auto defog, heated steering wheel Sporty and emotional Modern interior Target best in TCO Competitive pricing Product Concept

9 Product Concept

10 Product Concept

11 Cargo capacity cu. ft. (553 liters) with the rear seats occupied Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down Product Concept

12 Cd CO2 (g/km) ,082 22% 8,013 8,840 8,878 Predecessor i40 Competition Predecessor i40 Competition Predecessor i40 Competition Product Concept

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14 Full schedule predecessor 24M Model Fix Design Test SOP Model Fix Design Test SOP Full schedule i40 18M

15 Achieved a 7.6% reduction in BIW weight compared to predecessor kg -27.3kg EVI process Design optimization 438kg 438kg Design concept Final drawings Competition

16 Rearranging the part assembly allowed for a reduction of the material thickness From single part with uniform thickness to three parts with different, optimized thickness

17 Product Concept / Change of the form from linear interior to radial interior lead to a material thickness reduction Divergence angle to improve airflow and NVH performance Spare Member (1.0 ) Spare Member (0.8 )

18 Increased the torsional stiffness by 141% and the bending stiffness by 19%. Achieved 11% more torsional and 23% more bending stiffness compared to competition Predecessor i40

19 Continuous members from engine room to rear floor in longitudinal direction Connections of floor, sides and roof form closed circular structures Main joints optimized by extensions and closed profiles

20 The formation of a closed section connecting the underbody, cowl area and suspension strut improves the stiffness of the front-area This also increases the local stiffness of the suspension strut dome resulting in improved driving performance +87%

21 The vehicle rear end is reinforced by a double structure ring shape section The ring shapes are interconnected in longitudinal direction by the rear side members, waistline profiles and roof rails +67%

22 The roof stiffness is increased by local extensions Optimized energy flow through maximized overlap Increased local stiffness through constant section profile

23 Application of 71m of structural adhesives leads to body stiffness increase of 14%

24 MS ( MPa) HSS ( MPa) AHSS ( MPa) UHSS ( MPa) PHS ( MPa) Fibre reinforced plastic Hyundai Sonata i40 Euro at GDIS Car Body Conference Conference

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26 EuroNCAP comments: Driver knee airbag is standard equipment Maximum score for side barrier impact Bumper area scored maximum points for pedestrian protection Speed limitation assistance is standard equipment for best selling variant

27 24% 11% 100% 12% 89% 64% 4% 20% 12% 20% 4% 80% 14% 36% 30%

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29 1.3% 13.2% 21.1% 16.3% 12.0% 11.2% 12.3% 12.6%

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33 Product Concept World Car Concept Focused on local market customer demands Supporting Hyundai s philosophy of Modern Premium Featuring Hyundai s design language of Fluidic Sculpture BiW Concept Streamlined development process of 18 months CAE driven design for best performance and lowest cost Highly efficient use of High Strength Steels Excellent Light Weight Index to meet ecological demands Safe for Occupants and Pedestrians Product Concept

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35 North American Light Vehicle Metallic Material Trends PRESENTATIONS WILL BE AVAILABLE MAY 3 Use your web-enabled device to download the presentations from today s event Great Designs in Steel is Sponsored by: w w w. a u t o s t e e l. o r g