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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.

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I. IntroductionII. Special AppealIII. DQRIV. Safety

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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

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ADVANCED PERSONAL COMPACTADVANCED PERSONAL COMPACT

Trapezoid Lower Body

Wedged SilhouetteOne motion nose to cabin side

Aggressive & SolidFist like strength

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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

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I. IntroductionII. Special AppealIII. DQRIV. Safety

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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

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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

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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

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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

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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

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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

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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

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I. IntroductionII. Special AppealIII. DQRIV. Safety

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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

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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

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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

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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

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I. IntroductionII. Special AppealIII. DQRIV. Safety

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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

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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

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05M Civic05M Civic

Offset impact of Civic v. Pilot

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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

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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

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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

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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

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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

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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

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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

)

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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

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