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TRANSCRIPT
LIGHTWEIGHT SAVING SOLUTIONS
APPLIED ON
NEW PEUGEOT 3008
Sébastien CHOPARD
6th Annual Global Automotive Lightweight Materials Europe
AGENDA
GENERAL PRESENTATION
MATERIAL MIX
FOCUS ON B-PILLAR
FOCUS ON LOAD FLOOR
AGENDA
GENERAL PRESENTATION
MATERIAL MIX
FOCUS ON B-PILLAR
FOCUS ON LOAD FLOOR
GENERAL PRESENTATION
GENERAL PRESENTATION
I-Cockpit concept Opening roof
GENERAL PRESENTATION
+60 +62 +13
-15
114
+60
GENERAL PRESENTATION
GENERAL PRESENTATION
Mother car for:
5 Europe vehicles in 3 factories
4 China vehicles in 2 factories
4 brands
GENERAL PRESENTATION
Styling freedom on bodyside and rear area with same A pillar - B pillar and rocker reinforcer
GENERAL PRESENTATION
Roof rail improvement:
Laser brazed roof for perceive quality
Compact cross section
• Contribute to vehicle height reduction
• Maximize opening roof width
• More efficient shape for NVH
GENERAL PRESENTATION
High dynamic stiffness for NVH
First body mode :
• Continuous rear ring + Structural insert
• Rool up support and lower gusset
• Shear panel in rocker section
Upgrade prestations: Torsion dynamic stiffness
Stiff and light body to serve Peugeot driving dynamics
5 stars EuroNCAP 2016
GENERAL PRESENTATION
Lightweight index 𝑴
𝑲𝒕 ∗𝑨
AGENDA
GENERAL PRESENTATION
MATERIAL MIX
FOCUS ON B-PILLAR
FOCUS ON LOAD FLOOR
MATERIAL MIX
27,28%
31,01%
21,62%
0,20% 9,44%
1,50% 0,68%
0,68% 1,52%
0,79%
3,80%
1,47%
LSS
HSS
AHSS
UHSS
PHS
Sheet 6xxx
Sheet 5xxx
Extrusion 7xxx
Extrusion 6xxx
Duroplastic
Thermoplastic
Autre
Material mix of body and hang-on parts
Aluminium hood and fender
Full thermoplastic tailgate
MATERIAL MIX
Steel body with extended usage of PHS and AHSS
Duroplastic load floor as all EMP2 vehicles
25,88%
33,26%
28,24%
0,26% 11,12%
1,06% 0,19%
LSS
HSS
AHSS
UHSS
PHS
Duroplastic
Autre
MATERIAL MIX
Increased usage of PHS in the safety cage area:
DP steels both in stamping and roolforming:
3008
2 + 2 Parts
New 3008
10 + 10 parts
980 Mpa Stamped 1180 Mpa Roolformed 780 Mpa Stamped
MATERIAL MIX
Multi-thickness technology:
TRB TWB
MATERIAL MIX
Mass walk from 3008 to New 3008 BIW
250
260
270
280
290
300
310
320
330
340
350
-12%
AGENDA
GENERAL PRESENTATION
MATERIAL MIX
FOCUS ON B-PILLAR
FOCUS ON LOAD FLOOR
FOCUS ON B-PILLAR
308 3008
History construction B-Pillar : cutting of parts
Old 3008
FOCUS ON B-PILLAR
Old 3008 308 3008
History construction B-Pillar : material use
FOCUS ON B-PILLAR
AEMDB side crash scenario:
One piece TRB B-pillar with bending trigger in lower area
Strong roll-formed roof bow in DP 1180 grade
Sill bulkhead for seat cross member loading
PHS Diagonal door reinforcer
FOCUS ON B-PILLAR
Predictive calculation:
NOK
SAFE
RISK
FOCUS ON B-PILLAR
Correlation calcul – physical test:
FINAL SOLUTION ORIGINAL SOLUTION
AGENDA
GENERAL PRESENTATION
MATERIAL MIX
FOCUS ON B-PILLAR
FOCUS ON LOAD FLOOR
FOCUS ON LOAD FLOOR
SMC LOAD FLOOR
FINAL ASSEMBLY BODY SHOP ?
BODY SHOP
Assembly sequence:
Concept:
FOCUS ON LOAD FLOOR
FOCUS ON LOAD FLOOR
Welding point
Sealing
Glue and screw
Welding point
Sealing
BODYSHOP FINAL ASSEMBLY
Assembly:
Modularity:
FOCUS ON LOAD FLOOR
SMC STEEL
Modularity:
FOCUS ON LOAD FLOOR
FOCUS ON LOAD FLOOR
Synthesis:
≈ -35% weight saving
No process impact to manage steel and SMC versions
Less fixations
No crack in rear reparability crash
CONCLUSION
Vielen Dank
Thank you
ありがとう
Grazie
Merci