light-weighting options for vehicle structures for model year 2020

Light-Weighting Options for VehicleStructures for Model Year 2020

H. Singh – January 27th, 2012

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10

Fo 11 07/030/06/5© Copyright 2009 EDAG. Alle Rechte vorbehalten. / All rights reserved.

3

2

CAE Simulation Results comparison with test results

4 Vehicle System Weights and Light Weighting Options

1

5

6

Materials and Manufacturing Processes for High Volume Production

NHTSA Light Weighting Project

High Volume Production Cycle Time

Conclusions

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


How Much Mass Reduction is Feasible for a Midsize Sedan for Model Years 2017-2025?1. Baseline vehicle 2011 Honda Accord2. Identify light weighting technologies for 2020 model year

vehicle3. Cost no higher than 10% of current baseline vehicle’s MSRP4. Same vehicle performance and functionality5. All recommended technologies to be suitable for 200,000

annual production, 1 Million vehicles over 5 years6. Deliver a detailed CAE model to NHTSA suitable for further

safety related work

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


High Volume Production Cycle Time

200,000 Annual Production• 4,000 Weekly (50 Weeks per Year)• 800 Daily (5 Days per week)• 50 Hourly (16 Hours – 2 shifts)

One a Minute!

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Mass Saving Cost Boundaries for This Study

1. Vehicle Mass 1480.5 kg (Mid Size Sedan – Honda Accord)

2. Vehicle MSRP - $22,730

3. Manufacturing Cost - $14,700 (using RPE 1.47)

4. 10% Cost Increase; equivalent to $1,546

150 kg mass saving at $10.00 Per kg Mass Saving Premium

Or 300 kg mass saving at $5.00 Per kg Mass Saving Premium

10% Vehicle Mass Reduction leads to

approx 6.5% increase in fuel economy

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Materials Cost Comparison

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Materials &

Manufacturing Technology

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Manufacturing Assembly Technology

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Vehicle Pay Load – Mid Size Sedan (Honda Accord)

Mass (kg) Pay-load

Non Structural

Body Structure Chassis Power

train GVW

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865

21% 25% 18% 15% 21%

OccupantsLuggageTowing (1000 lbs)

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Non Structural Weight

Mass (kg) Pay-load

Non Structural


train GVW

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865

21% 25% 18% 15% 21%

SeatsAirbags and restraintsInterior TrimInstrument PanelEntertainmentHeating & Air-conditioningClosures

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Chassis Weight

Mass (kg) Pay-load

Non Structural


train GVW

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865

21% 25% 18% 15% 21%

Front and rear suspensionsBrakes SystemWheels & Tires

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Powertrain

Mass (kg) Pay-load

Non Structural


train GVW

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865

21% 25% 18% 15% 21%

Engine & Transmission Drive-shafts Exhaust SystemFuel System

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Body Structure Weight

Mass (kg) Pay-load

Non Structural


train GVW

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865

21% 25% 18% 15% 21%

Body StructureFront & Rear Bumpers

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


LWV Design OptionsBody Structure and Closures

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Body Structure Options

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Front Doors

Option 2 – Magnesium HPD Casting

Combine several partsWill require high tonnage press

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Light Weight Vehicle - Body and Closures

Aluminum Hood Assembly

(-7.5 kg)

Aluminum deck lid assembly (-4.9 kg)

Aluminum fenders (-3.6 kg)

Aluminum rear door assemblies (-11.5 kg)

Optimized Advanced High Strength

Steel Body Structure (-82 kg)

Aluminum front door assemblies (-15.2 kg)Hot Stamped Bumper

(-3.6 kg)

Hot Stamped Bumper(-3.5 kg)

Honda Accord (kg)

LWV (kg)

438.5 308.4

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Light Weight Vehicle - Body and Closures – Material Selection

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Light Weight Vehicle Chassis

Honda Accord (kg)

LWV (kg)

287.8 206.1

Aluminum cradle assembly

(-20.7 kg)

Aluminum K frame assembly

(-11.2 kg)

Various materialassembly (-2.1 kg)

Wheels & tires (-14.2 kg)

Macphersonvarious materials

(-15.3 kg)

Steering system (-4.8 kg)

Brake system (-18.2 kg)

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Light Weight Vehicle – Powertrain resized for same performance

Honda Accord (kg)

LWV (kg)

383.3 311.7

Down Sized from 2.4L to 1.8L (-28.6 kg)

5 speed automatic (-27.9 kg)

Exhaust (-1.7 kg)

Drive shafts (-3.5 kg)

Fuel tank (-1.8 kg)

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Magnesium IP Beam

(-5.3 kg)

Magnesium/ Composite Back Panel

(-6.2 kg)

Magnesium intensive Frame

(-7.5 kg per seat)

Instrument Panel (-4.2 kg)

Light Weight Vehicle - Interior

Honda Accord (kg)

LWV (kg)

370.4 317.6

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Computer Optimization of LWV

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Vehicle Light WeightingTopology Optimization

LWV Structure

Topology Optimization – predicted load paths

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Vehicle Light Weighting3G Optimization (Gauge, Grade & Geometry)

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Vehicle Light Weighting3G Optimized – Section Comparison

Rocker Section Comparison – Body structure

LWV

Baseline Honda Accord

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


CAE Analysis on LWV is performed and correlated with Honda Accord 2011 for following Stiffness & crash tests:

Torsional and Bending Stiffness Normal Mode Frequencies USNCAP Frontal Rigid Barrier 35 mph test IIHS offset barrier 40 mph deformable barrier test USSINCAP Lateral side impact test IIHS Side Impact 50 km/h test NCAP Rigid Side Pole 20 mph test IIHS Roof crush test Rear 301 fuel tank integrity 50 mph test

CAE Analysis Results for Light Weight Vehicle

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Light Weight Vehicle FEA Model

Number of Parts 702

Number of Beams 4,763

Number of Solids 272,214

Number of Shells 1,210,307

Number of Nodes 1,403,378

Total Number of Elements 1,487,424

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


NVH and Stiffness Comparison

Description Honda Accord Test - stiffness

LWV Target stiffness LVW stiffness

Torsion stiffness (KN-m/deg) 12.33 12.5 16.25

Description Honda Accord Test - stiffness

LWV Target stiffness LVW stiffness

Bending stiffness (N/mm) 8,690 9,000 12,636

Frequency type Target Frequency (Hz)

LWV Frequency (Hz)

Front end lateral mode 35.10 41.78

Second order bending mode 39.30 41.12

First order bending mode 44.20 47.18

Torsion mode 50.10 48.97

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Results of EDAG LWV crash model for this crash test has been correlated with Honda Accord 2011 test # 7078 done by MGA research corporation.

Curb weight of the LWV crash model = 1150 kg Weight of 50th percentile male dummy on driver seat = 80 kg Weight of 5th percentile female dummy on front passenger seat = 50 kg Weight of instrumentation in the rear cargo area= 45 kg Total test weight of the LWV Crash Model = (1150+80+50+45)= 1325 kg

Total test weight of Honda Accord 2011 crash test ( Test # 7078) = 1669 kg

USNCAP Frontal Rigid Barrier 35 mph Test

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10



LWV - CAE Simulation

Honda Accord 2011 Test # 7078

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10



Honda Accord 2011 Test # 7078

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Crash pulse comparison of the Honda Accord 2011(Actual Test) and EDAG LWV

Occupant compartment intrusion comparison


http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


LWV – Mass Saving Summary

Mass (kg) Pay-load

Non Structural


train GVW CVW MSRP

Honda Accord - 2011 385 465.1 343.8 287.8 383.3 1865 1480 $22,730

LWV 385 366.5 261.1 206.1 311.7 1530 1145Mass

Reduction -21.2% -24.1% -28.4% -18.7% -17.9% -22.6%

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


1. This study helps to demonstrate that mass reduction of up to 23% is likely feasible, that maintains performance and safety functionality and MSRP at +10% of the original baseline midsize sedan.

2. The approach for this study is an evolutionary implementation of advanced materials and manufacturing technologies currently used in the automotive industry.

3. The recommended materials (Advanced High Strength Steels, Aluminum, Magnesium and Plastics) manufacturing processes (Stamping, Hot Stamping, Die Casting, Extrusions, Roll Forming, Hydroforming) and assembly methods (Spot welding, Laser welding and Adhesive Bonding) are at present already used, some to a lesser degree than others.

4. The recommended technologies should be able to be fully developed within the normal ‘product design cycles’ using the current ‘design and development’ methods prevalent in the automotive industry.

Conclusions

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Partner Companies

Since its inception, Electricore has had a successful history of collaboration with the departments of Defence, Energy and Transportation in the development, demonstration and deployment of advanced technologies.

Chartered in 1992, the NCAC at The George Washington University's Virginia Campus is one of the nation's leading authorities in automotive and highway safety research.

http://www.sae.org/

http://www.sae.org/

EDAG Inc. 1-4-10


Thank you for your Attention

http://www.sae.org/

http://www.sae.org/

light-weighting options for vehicle structures for model year 2020

Documents

alle rechte vorbehalten

vehicle mass reduction

studyvehicle mass

manufacturing costs

materials cost comparison

weighting program

annual production

cost increase equivalent