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
Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars
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%
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
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
Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars
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
Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars
Highly Engineered Bumper Systems FEA Model Centerline (C/L) Load Case Bumper System 38.8 mm Overlap IIHS Curved Barrier
Exploded FEA Model Highly Engineered Bumper Systems Crush Can Mounting Plate Bumper Beam
P-tech Beam @ 1.55mm Mass: 4.86 kg Highly Engineered Bumper Systems 1.55 mm gage C/L Section Bumper Beam
Highly Engineered Bumper Systems New Technology Beam@1.7mm top /1.2mm bottom Mass: 4.548 kg 1.7 mm gage C/L Section Bumper Beam 1.2 mm gage
Laser Welded 1.7/1.2 mm vs. 1.55 mm Highly Engineered Bumper Systems
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 0.312 Kg lower mass for C/L Barrier load case Laser Welded Proposal Provides a 14% Mass Savings
Laser Welded 2 : 2.0 mm 80 Ksi Mass: 8.703 Kg Highly Engineered Bumper Systems 2.0 mm Thick, 80 Ksi Material C/L Section Bumper Beam
Highly Engineered Bumper Systems Laser Welded 2 : 2.0 mm 80 Ksi (TOP), and 1.2 mm M190 (BOTTOM) Mass: 6.963 Kg 2.0 mm Thick, 80 Ksi Material 1.2 mm Thick, M190 Material C/L Section Bumper Beam
Highly Engineered Bumper Systems
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 99.2 94.7 2 Laser Welded Proposal 2: 2.0 mm 80 Ksi(TOP), and 1.2 mm M190(BOTTOM) Bumper Beam 102.2 104.5 S. No. Bumper System Mass (Kg) % Mass Saving 1 Baseline: Uniform 2.0 mm thick, 80 Ksi Bumper Beam 8.703-2 Laser Welded Proposal 2: 2.0 mm 80 Ksi(TOP), and 1.2 mm M190(BOTTOM) Bumper Beam 6.963 20%
Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars
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
Door Intrusion Beams Simulation Study Industry Leading Section Animation through 6 Intrusion
Door Intrusion Beams Simulation Study Constant Circular Section Animation through 6 Intrusion
Door Intrusion Beams Simulation Study New Tech Section Animation through 6 Intrusion
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 2.20 1.676 2401 1433 Constant closed circular section 2.1 1.66 2219 1337 New Tech Section @ 2.55 2.55 1.673 2559 1530
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 2.20 1.676 8,189 4,886 Constant Closed Circular Section 2.1 1.66 8,011 4,826 New Tech Section @ 2.55 2.55 1.673 10,274 6,141
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
Outline P-Tech Process Review Technology Merge Highly Engineered Bumpers Intrusion Beams Safety Engineered Laser Welded B-Pillars
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.
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
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 1110.3 mm 1126.7 mm
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
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