advanced high strength steel technology in the 2006 honda .../media/files/autosteel/great...05m...
TRANSCRIPT
w w w . a u t o s t e e l . o r g
Advanced High Strength Steel Technology in the 2006 Honda Civic
Creating Special Appeal with SteelCreating Special Appeal with Steel
Mark PafumiHonda R&D Americas, Inc.
w w w . a u t o s t e e l . o r g
I. IntroductionII. Special AppealIII. DQRIV. Safety
w w w . a u t o s t e e l . o r g
I. IntroductionII. Special AppealIII. DQRIV. Safety
New Civic Grand Concept
BalanceBalance
Advance Personal Compact
Innovative Package Designand
Advanced Performance
Innovative Package Designand
Advanced Performance
Providing a Unique Civic
Feel and Impression
Providing a Unique Civic
Feel and Impression
DQR EnvironmentSafety
Special Appeal
Exterior Design ConceptExterior Design Concept
SPORTY ONE MOTION FORMSPORTY ONE MOTION FORM
■ FORWARD CABIN■ FORWARD CABIN
ADVANCED EMOTIONAL DESIGNADVANCED EMOTIONAL DESIGN
■ SOLID & Hi-TENSION BODY■ SOLID & Hi-TENSION BODY
Exterior DesignExterior Design
w w w . a u t o s t e e l . o r g
ADVANCED PERSONAL COMPACTADVANCED PERSONAL COMPACT
Trapezoid Lower Body
Wedged SilhouetteOne motion nose to cabin side
Aggressive & SolidFist like strength
w w w . a u t o s t e e l . o r g
Coupe vs. Sedan Packaging DifferencesCoupe vs. Sedan Packaging Differences
MORE SPORTY STANCE!MORE EMOTIONAL STYLE!
Coupe is clearly distinguished from the Sedan
-50mm
- 50mm-20mm
Hip PointWheelbase
Windshield
-2o
Sporty&
Sharp
w w w . a u t o s t e e l . o r g
I. IntroductionII. Special AppealIII. DQRIV. Safety
w w w . a u t o s t e e l . o r g
White body weight = +4%
• ACETM (Front) Body Structure
• Side Impact Improvements
• Rigidity (for handling)
• Side Air Bag
• Side Curtain Air bag
• 16” wheels
• 1.8L (larger) Engine
• 5-Speed Automatic
• Telescoping Steering
New Features
Weight Summary
• Body Structure +16 kg
• Features + 46 kg
Target: Increase overall dimensions and add featuresTarget: Increase overall dimensions and add features
White Body Overview
05M Civic05M Civic
w w w . a u t o s t e e l . o r g
HSS Usage Rate: 32% HSS Usage Rate: 50%
50%
9%3%
38%68% 2%
19%
11%
590440340270
Grade590440340270
Grade
05M Civic05M Civic
50% of body now high strength steel
590 MPasteel use tripled
Target: Improve performance and control weight through HSSTarget: Improve performance and control weight through HSS
High Strength Steel Utilization
w w w . a u t o s t e e l . o r g
Front Styling
Target: Realize Target: Realize ““OneOne--motionmotion”” and and ““CrouchingCrouching”” form stylingform styling
05M Coupe05M Coupe = 26.7o
[NSX = 23.9o]
W/S angle -18%
1045 mm
881 mm
23.9o23.9o
Sedan
21.9o21.9o
Coupe
05M Sedan05M Sedan = 29.1o
WindshieldWindshieldAngle -18%
Glass area +25%
Length of Front EndLength of Front End@ Center line -16%
05M Civic
w w w . a u t o s t e e l . o r g
Dashboard Upper Construction
05M Civic05M CivicTarget: Apply aggressive front styling and improve structural rTarget: Apply aggressive front styling and improve structural rigidityigidity
05M Civic05M Civic
Rigid ConnectionDA/BD UPR Lid
260 mm
Engine
Apply DA/BD UPR lidApply DA/BD UPR lid
• DA/BD UPR extends over engine
• Lid removable for service
• Wiper box ties damper house together
Move base of windshield outMove base of windshield outDamper house connection to DA/BD UPR less rigid
Extends over engine
w w w . a u t o s t e e l . o r g
Side Sill Design
Under-cut formed by cam
Target: Economically improve styling and acoustics of side sillTarget: Economically improve styling and acoustics of side sillPlastic GarnishPlastic Garnish
Acura TSX+ Clean appearance+ Good acoustics (chipping noise)-- High cost
05M Civic05M CivicSlope-type Side Sill
- Visible weld flange- Low impact damping (chipping noise)++ Low cost
Conventional PVC
Edge-type Side Sill
PVC-free acoustic (expandable) coating
+ Same appearance as plastic garnish+ All steel design – no assembly parts+ Good chipping noise+ Low cost
w w w . a u t o s t e e l . o r g
Lower body accents
Theme: Simulated body side cladding Theme: Strong lower character line that doubles as door protector
CoupeCoupe SedanSedan
“Cladding” molded in front & rear bumpers
• Character line creates shadow giving appearance of a body kit
• Side panel flared at RR wheel to provide air foil effect
• Unique look with zero cost!
Body side “molding” molded in bumper
• Front and rear doors apply clip-on plastic molding
• Front fender and side panel stamp shape of protector
•Unique look achieved with only two clip on garnishes
Target: Economically apply modelTarget: Economically apply model--exclusive lower body accentsexclusive lower body accents
w w w . a u t o s t e e l . o r g
Rolled Rear Wheel Arch
Target: Guarantee compatibility of wide track and tire clearancTarget: Guarantee compatibility of wide track and tire clearancee• Rear wheel arch rolled after welding
• Allows tires to be pushed outward as far as possible
SECTION AA
After bending
Bend angle: 65°
Dust sealer
RR Inner Panel
Side Panel Outer
Bending range
A
A
w w w . a u t o s t e e l . o r g
I. IntroductionII. Special AppealIII. DQRIV. Safety
w w w . a u t o s t e e l . o r g
Front Subframe
1.8L Engine1.8L Engine 2.0L Engine (2.0L Engine (Si Si ))Specifications 1.8L 2.0L
Material 440 MPa 270 MPa
Process Hydro Stamped
Thickness 2.0t 2.0t
Weight 20.4 kg 22.4 kg
Production location JP, US Thailand
World-wide volume 450,000 50,000
Bending Moment of Inertia(XY coodinates)
Ix-x 69472
M=(31*57213)/17
=126685 [kgmm]
17mm
Bending Moment of Inertia(XY coodinates)
Ix-x 121548
M=(21*121548)/20
=127625 [kgmm]
20mm
(Yield Strength 31kg/mm2) (Yield Strength 21kg/mm2)
Straight pipe
• Economical tooling
• Conventional design
• One worldwide source
Efficient section
• Optimized design – low piece price
• Expensive tooling – but high volume
• AHSS allows same bending moment
Target: Develop two Target: Develop two subframessubframes with different design constraintswith different design constraints
w w w . a u t o s t e e l . o r g
Target: Improve body mounting strength for sporty suspensionTarget: Improve body mounting strength for sporty suspension• Reinforced for improved suspension mounting point rigidity• Extra toughness for aftermarket modifications• Must keep common layout to base model
Increase thickness RR Stabilizer Mount
2.3t 3.2t
Extend UPR Arm BRKT
Add SWs
Extend Internal Bulkhead
Modify RR Crossmember
bulkhead
Rear Crossmember
Exclusive application Exclusive application for for Si Si CoupeCoupe
RR CrossmemberRR Crossmember EXTN UPR Arm
BRKT
RR Stabilizer Mount Brkt
RR Crossmember - 1.2t/270 MPa
CountermeasuresCountermeasures
Spot weld life increased 8xSpot weld life increased 8x
w w w . a u t o s t e e l . o r g
0.8t
1.2t/590 MPa
1.8t
1.2t
Add DA/BD UPR Gusset
Increase section of
Side Frame to UPR
Member connection
Add 2-piece FR Seat Cross
Member
Add Side Sill EXTN
Add RR Tray to RR Inner
Gusset
B-PLR LWR
Increase thickness of Center
Tunnel Frame
ResultResult
Mode vs. 05M Civic05M Civic
Bending + 7.6%
Torsion + 11%
Body Rigidity
Torsion
590 MPa
Target: Improve body rigidity with focus on connection detailsTarget: Improve body rigidity with focus on connection details
w w w . a u t o s t e e l . o r g
Rear Parcel Tray Construction
Target: Control vibration input from 360W subwooferTarget: Control vibration input from 360W subwoofer• Improves rattle/squeak toughness
• Prevents center seat belt retractor chatter
Add bent flange around speaker & seat belt holes
Add strap (0.6t)Maximize speaker hole diameter
Com
plia
nce
(m/N
–dB
)
Subwoofer Operating Frequency (40-160 Hz)
C/M #1BaseFinal
Rear Tray mode with glassAdd beads
0.6t/270 MPa
Sect AA
0.6t/270 MPa
5 mm
0.6t/270 MPa
Add support (1.6t)
Section AA
Box section
w w w . a u t o s t e e l . o r g
I. IntroductionII. Special AppealIII. DQRIV. Safety
w w w . a u t o s t e e l . o r g
FrontFront
SideSide
RearRear
SideSide
Target: Create highTarget: Create high--energy absorbing structure with HSSenergy absorbing structure with HSS
All critical frame members use 590 MPa steel
Safety
w w w . a u t o s t e e l . o r g
ACETM Body Structure
05M Civic05M Civic
Extended upper member joined to the side frame
Cross section of upper member joint enlarged
Load Distributing Body Frame
Load carried deep in to structure
Target: Adopt advanced Compatibility Body StructureTarget: Adopt advanced Compatibility Body Structure
w w w . a u t o s t e e l . o r g
05M Civic05M Civic
Offset impact of Civic v. Pilot
w w w . a u t o s t e e l . o r g
Target: Efficient transfer of frontal crash loadsTarget: Efficient transfer of frontal crash loads
Floor frame extends to side sill
1.0t/590 MPa1.6t/590 MPa
05M Civic05M Civic
Floor frame stops
1.6t/590 MPa
Photo courtesy IIHS Load transfer to side sill
64 KPH Offset Barrier
Floor Frame Construction
w w w . a u t o s t e e l . o r g
Tailor Welded Blanks
1.2t
1.4t
1.6t
Target: Apply tailor welded blanks to balance performance & weiTarget: Apply tailor welded blanks to balance performance & weightght• Dashboard Lower
• Front Side Frame
• Door Inner Panel
• Center Pillar Stiffener (4D)
Dashboard LowerDashboard Lower
Front Side FrameFront Side Frame
05M Civic05M Civic
Apply beads to increase rigidity of section
590 MPa
0.8t/270 MPa
1.2t/590 MPa
Polygon shape
w w w . a u t o s t e e l . o r g
Side Impact Test Modes
Passenger Car Mode Light Truck Mode
WT: 3015 lbs WT: 3300 lbs (+285 lbs) 15 in (+4 in)
• Higher Weight• Higher Height
11 in
Rib maxG + Lwr Spine G2
TTI =Rib G
Lower Spine G Rib Deflections
Pelvic Forces
Neck Force/Moments
Head Injury CriteriaTwo Body Regions rated to
calculate Thoracic Trauma Index (TTI)Head G
Pelvis G
Four Body Regions rated
• Barrier strikes low – engages side sill and B-PLR
• Two body regions rated
• No rating for structure or head protection
NHTSA Side NCAP IIHS SICE
• Barrier misses side sill – all load carried by door & B-PLR
• Four body regions rated
• Head protection & body performance rated
IIHS “GOOD”Driver
Target: Achieve high performance in both NCAP & IIHS modesTarget: Achieve high performance in both NCAP & IIHS modes
w w w . a u t o s t e e l . o r g
Side Impact Protection
ARCH A, ROOFHSS MPa, t0.7
GUSSET,MID FLR C/MBRHSS MPa, t2.6
PNL,RR INSIDE270MPa, t0.65
RNFCT, MID FLR C/MBRHSS MPa, t 2.0
STIFF,CTR PLR LWRHSS MPa, t1.0
GST, ROOF ARCHHSS MPa, t1.6
RNFCT,CTR PLR LWR270MPa, t1.6
STIFF,CTR PLR UPHSS MPa, t2.0
RNFCT,CTR PLR UPHSS MPa, t1.0
RNFCT B, CTR PLR LWRHSS MPa, t1.6
05M Civic05M Civic
STIFF,CTR PLR270MPa, t2.0
RNFCT,GUSSETHSS MPa, t2.0
RNFCT,MID FLR C/MBRHSS MPa, t1.6
ARCH A, ROOF270MPa, t0.7
GUSSET,MID FLR C/MBRHSS MPa, t3.0
PNL,RR INSIDE270MPa, t1.2
C/MBR,MID FLR STIFFHSS MPa, t1.6
Weight = -3.9 kg; Cost = -10%53% HSS (by weight) 89% HSS (by weight)
Target: IIHS Good with reduced weight and costTarget: IIHS Good with reduced weight and cost
w w w . a u t o s t e e l . o r g
Rear Impact (RR301)
05M Civic05M CivicBent
Straight
FR
Target: Efficient energy absorption of rear frameTarget: Efficient energy absorption of rear frame• Phase in RR301 regulation (80 kph RR impact)• No damage to fuel tank• Protect fuel filler pipe from leak
RR Frame Stiffener2.3t/590 MPa
RR Frame2.0t/590 MPa
RR Upper Arm Brkt1.8t/270 MPa
RR Floor Cross Mbr Extn
1.8t/270 MPa
RR Frame Patch0.6t/270 MPa
Rear FrameRear Frame
Fuel tank
Fuel filler pipe
Fuel SystemFuel System
Frame ConstructionFrame Construction
w w w . a u t o s t e e l . o r g
Pedestrian Impact
Hood HingeHood Hinge
HoodHood
• Verically collapsable structure• Still must meet durability & frontal crash requirements (no windshield contact)
Wiper Pivot (Aluminum)Wiper Pivot (Aluminum)
Fender BracketFender Bracket
• Break-away Structure
• Collapsable fender mounting• Clearance to UPR MEMBERMeets EU/J regulation:
66% of area <1000 HIC100% of area <2000 HIC
Target: Reduce head injury by applying:Target: Reduce head injury by applying:• Energy absorbing structure• Sufficient clearance to underhood components
Initiator Holes
w w w . a u t o s t e e l . o r g
Safety Summary
Pass
Driver
GOOD
GOOD
GOOD
Test Mode Published Data
Driver
Pass
Front
Rear
Front NCAP
Side NCAP
Offset
Side Impact
Neck Injury Reduction
GO
LD (
06M
)
w w w . a u t o s t e e l . o r g
Conclusion
Special AppealSpecial Appeal• Lightweight white body
• 50% high strength steel
• Aggressive front styling
• Unique DA/BD UPR construction
• Integrated side sill design
• Stylish lower body accents
• Rolled wheelarch flange
DQRDQR• Flexible front subframe design
• Rigid rear parcel tray
• Durable rear crossmember
• Enhanced body rigidity
SafetySafety• ACETM body structure
• Energy distributing floor frame
• Extensive use of tailored blanks
• Efficient side impact structure
• Industry-leading pedestrian impact protection
All made possible with innovative use of steelAll made possible with innovative use of steel
w w w . a u t o s t e e l . o r g