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GDIS2017
Highlights
INTEGRATED COMPUTATIONAL MATERIALS
ENGINEERING APPROACH TO DEVELOPMENT OF
LIGHTWEIGHT 3GAHSS VEHICLE ASSEMBLY
• Principal Investigator: Dr. Lou Hector Jr. (GM)
• 4+ Year Project - Feb. 1, 2013 – Mar. 31, 2017
• $8.5 Million - $6M DOE, $2.5M Cost Share
• Participants: - 5 universities - 1 national laboratory
- 3 steel companies - 3 automotive OEMs
- 2 engineering firms
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Participants
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Steel Strength Ductility Diagram
• Two 3GAHSS steels were developed for model validation and design optimization.
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3GAHSS
• The two 3GAHSS alloys were used for:
Material Model Validation Forming Model Validation Design Optimization
1600
1400
Engineering stress (MPa)
1200
1000
800
200
0
0.00 0.05 0.10 0.15 0.20
Engineering strain
Phase distribution
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Task 5 – Program Requirement
Baseline Assembly
Applicants shall establish a baseline vehicle assembly for comparison. The baseline
vehicle assembly description shall include the assembly description, its materials of
construction, and weight. Baseline vehicle components shall have been available on
a similarly configured 2006 or later commercially available Light Duty production
vehicle. Light Duty vehicles include any of the following automobiles: passenger
vehicles, light duty trucks, sport utility vehicles, or passenger vans.
Weight Cost per Pound of
Vehicle Additional
System Definition (1) Reduction Weight Saved ($/lb
System Requirements
Target (2) saved) (2)
Body-in-White, Closures, Replacement
Body Windows, Fenders, & Bumpers ≥35% ≤$3.18/lb Technology must
achieve Function and
Suspension, Steering, Wheels, & Packaging
Underbody Structural Requirements of
Chassis ≥25% ≤$3.11/lb Technology to be
Components
Replaced
(2)
Note : When compared to a 2006 or Later Production Light Duty Vehicle Technologies.
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EDAG - Statement of Work
Establish Baseline Assemblies:
1. Select Assemblies
2. Load Cases and Performance Targets (Stiffness, Normal Modes, Crashworthiness)
3. Prepare Detailed FEA Models
4. Cost Model
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LSDYNA Model for Crash Performance
No Sub System Structure
Mass (kg) Subsystem
1 BIW 331.6 represented as
2 Glass 26.2
3 BIW Adhesives 5.0 nodal masses
4 Door Front Left 28.7 (purple spots) ,
5 Door Front Right 28.7
6 Door Rear Left 26.1
constraint with
7 Door Rear Right 26.1 interpolation
8 Rear Suspension 129.7 constraints (blue
9 Front Suspension 157.8
10 Powertrain 296.1 webs)
11 Steering Column 22.3
12 IP Beam 42.8
13 Front Seat Left 25.0
14 Front Seat Right 23.2
15 Hood 16.2
16 Deck Lid 20.0
17 Fuel tank 74.2
18 Radiator 37.9
19 Rear Bumper/Fascia 17.8
20 Rear Seat System 21.0 Vehicle COG
21 Occupants 140.0 X 2827.7
22 Paint / Latches / Trims /Fenders 93.4
TOTAL 1589.8
Y 20.4
Z 514.5
Crash Model System Masses
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LSDYNA – Modeling Considerations
For crash load cases, initial velocities are reduced so that the new internal energy is 70% of the total internal
energy using standard regulation velocities. This is because the model is for a BIW only (i.e., not a full vehicle
system model). The 30% energy reduction is a judgment based on experience with prior projects.
Target numbers:
• B-Pillar Velocity & Intrusion
20 mph 16.7 mph • Roof Rail / Rocker Intrusion at Impact
-30%
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Baseline Performance Results set as Targets
CAE Load Cases
1. Side Barrier
2. Side Pole
3. Front Impact
4. Rear Impact
5. Roof Crush
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Body Side Assembly – design iter-3
̶ Max. mass saving while meeting crash performance, by
Rocker Front Joint:
substituting 3GAHSS properties
̶ Min. gauge assumed 0.6 mm Four Stamped Parts
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Body Side Assembly – design iter-6
̶ Increase joint stiffness by removal of panel joints
̶ Take advantage of increased formability of 3GAHSS
Rocker Front Joint:
Replace 4 parts with 2
Laser Welded Blank
Stampings
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LSOPT Setup for iter-7
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LS-OPT Setup for iter-8 (from iter-7)
Geometry optimization
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Geometry Optimization Setup
• Focusing on 4 areas
− B-Pillar Reinforcement
− A-Pillar Reinforcement
− Inner Rocker
− Outer Rocker
• Will not change outer styling or
reduce packaging space
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Results for iter-9
Iter-9 results –
1. Meet all performance targets
2. Further mass saving limited by
stiffness
3. Superior crash performance due
to higher strength of 3GAHSS
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Final 3G Optimization - NREL
• Objective
− Mass Optimization
• Constraint
− Baseline crash and NVH targets
• Variables
− 62 Morphing points , 32 Thickness
variables, 32 Material Variables
• Job time estimate for EDAG cluster (480 CPU)
− 4.2 month @ 100% cluster utilization for
15 iterations, 189 designs per load-
case 19,845 runs for 15 iterations
• Software used
− LSOPT, LSDYNA -ICME (Explicit and
Implicit)
− Beta - ANSA ; www.ansa-usa.com
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NREL HPC Setup
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Optimization Variable Setup for 3G Optimization
• 64 parts total
• Thickness
• Min = 0.55mm
• Max = 2.0mm
• Material*
• 10% Mn Steel
• 3% Mn Steel
• Geometry
• Rocker
• B-Pillar
• A-Pillar
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Optimization Performance
333
330
Body side assembly
mass
BIW Mass (kg)
327
324
67.5 kg – optimized mass
321
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Final Optimized Model
Final Model –
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Rocker Profile Animation
Baseline
Optimized Top View
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Process Driven - Technical Cost Modeling
What it is:
— An objective way to compare technologies, designs or manufacturing methods
— An analysis of manufacturing, equipment, tooling, labor, material, and energy costs
— A process to identify cost drivers
— A method to integrate piece cost, tooling cost and capital investment.
What it isn’t:
— A precise method to obtain commercial price
— A business case
— An analysis of non-manufacturing overhead, such as prototype costs, logistics,
engineering and development costs
ICME Project Specific Assumption
The cost estimates used are not specific to any OEM and are based on industry
estimates. Specific OEMs will have varying estimates that include (but not limited to)
manufacturing flexibility, safety safe-guards, regional impacts, and vehicle variant
manufacturing strategy etc.
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Baseline - Body Side Assembly LH Sequence
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3GAHSS Cost Estimate per kg
Tubes
Tailor Multiwall
Ref Straight
Thickness (mm) Grade HDG Visible Rolled Tube Tool Line Reject
Material as
Item # Steel Grade Coil Blank Investmt Rate Rate
Price shipped
Factor Factor Factor
($/kg) Premium Premium Premium Premium Premium Premium
Min t Max t
($/kg) ($/kg) ($/kg) ($/kg) ($/kg) ($/kg)
1 Mild 140/270 0.35 4.60 0.82 0.00 0.06 0.05 0.55 0.25 0.65 1.0 1.0 1.0
2 BH 210/340 0.45 3.40 0.05 0.06 0.10 0.55 0.25 0.65 1.05 0.95 1.05
3 BH 260/370 0.45 2.80 0.05 0.06 0.10 0.55 0.25 0.65 1.05 0.95 1.05
4 BH 280/400 0.45 2.80 0.07 0.06 0.10 0.55 0.30 1.10 1.05 0.95 1.05
5 IF 260/410 0.40 2.30 0.07 0.00 0.10 0.55 0.30 0.70 1.05 0.95 1.05
6 IF 300/420 0.50 2.50 0.10 0.00 0.10 0.55 0.30 1.10 1.05 0.95 1.05
7 HSLA 350/450 0.50 5.00 0.12 0.10 NA 0.55 0.30 1.50 1.05 0.95 1.05
8 HSLA 420/500 0.60 5.00 0.14 0.10 NA 0.55 0.45 1.25 1.10 0.90 1.10
9 HSLA 490/600 0.60 5.00 0.16 0.10 NA 0.55 0.45 1.65 1.10 0.90 1.10
10 HSLA 550/650 0.60 5.00 0.35 0.10 NA 0.55 0.45 1.65 1.10 0.90 1.10
11 HSLA 700/780 2.00 5.00 - - - - - - - - -
12 SF 570/640 2.90 5.00 0.35 0.10 NA NA 0.45 2.05 1.10 0.90 1.10
13 SF 600/780 2.00 5.00 0.35 0.10 NA NA 0.45 2.05 1.10 0.90 1.10
14 TRIP 350/600 0.60 4.00 0.40 0.10 NA NA 0.45 1.25 1.10 0.90 1.10
15 TRIP 400/700 0.60 4.00 0.45 0.10 NA NA 0.45 1.65 1.10 0.90 1.10
16 TRIP 450/800 0.60 2.20 0.50 0.10 NA NA 0.50 1.30 1.15 0.85 1.15
17 TRIP 600/980 0.90 2.00 0.55 0.10 NA NA 0.55 1.35 1.15 0.85 1.15
18 FB 330/450 1.60 5.00 0.20 0.10 NA 0.55 0.30 1.10 1.05 0.95 1.05
19 FB 450/600 1.40 6.00 0.25 0.10 NA 0.55 0.45 1.65 1.10 0.90 1.10
20 DP 300/500 0.50 2.50 0.20 0.10 0.10 0.55 0.45 0.85 1.10 0.90 1.10
21 DP 350/600 0.60 5.00 0.26 0.10 0.10 0.55 0.45 1.25 1.10 0.90 1.10
22 DP 500/800 0.60 4.00 0.31 0.10 NA 0.55 0.50 0.90 1.15 0.85 1.15
23 DP 700/1000 0.60 2.30 0.38 0.10 NA NA 0.55 0.95 1.15 0.85 1.15
24 DP 800/1180 1.00 2.00 - - - - - - - - -
25 DP 1150/1270 0.60 2.00 0.38 0.10 NA NA 0.55 0.95 1.15 0.85 1.15
26 CP 500/800 0.80 4.00 0.31 0.10 NA NA 0.50 1.30 1.15 0.85 1.15
steel used in the cost model for cold rolled (CR) mild 30
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CP 1000/1200
CP 1050/1470
0.80
1.00
2.30
2.00
0.47
0.47
0.10
0.10
NA
NA
NA
NA
0.60
0.60
1.40
1.80
1.20
1.20
0.80
0.80
1.20
1.20
32 MS 950/1200 0.50 3.20 0.47 NA NA NA 0.60 1.00 1.20 0.80 1.20
(www.platts.com). 36
37
HF 1050/1500 (22MnB5)
10Mn 980
0.60
0.60
4.50
3.00
0.75
0.65
NA
0.10
NA 0.55 0.65
0.60
1.05 1.20
1.20
0.80
0.80
1.20
1.20
38 3Mn 1500 0.60 3.00 0.53 0.10 0.60 1.20 0.80 1.20
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3GAHSS Cost Estimate per kg
UTS Delta
Premium Steel Grade
MPa ($/kg)
TRIP Cost
$0.70
Delta cost TRIP 350/600 600 $ 0.40
$0.60
TRIP 400/700 700 $ 0.45
estimate for: TRIP 450/800 800 $ 0.50
$0.50
$0.40
TRIP 600/980 980 $ 0.55
$0.30
TRIP X/1200 1200 $ 0.65 400 600 800 1000 1200
10Mn - $0.65/kg
UTS Delta
Steel Grade
MPa ($/kg) Complex Phase Cost
CP 500/800 600 $ 0.31 $0.55
CP 600/900 700 $ 0.35 $0.50
CP 750/900 800 $ 0.40 $0.45
CP 800/1000 980 $ 0.45 $0.40
CP 1000/1200 1200 $ 0.47 $0.35
CP 1050/1470 1470 $ 0.47 $0.30
3Mn - $0.53/kg CP 1500 1500 $ 0.53 400 600 800 1000 1200 1400
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Accomplishments
• Baseline Design: 94.6 kg. $1.26/lb
• 3GAHSS Design: 66.7 kg.
• Mass savings: 27.9 Kg. (-30%)
• Parts reduced from 46 to 28
• Cost increase $ 20.90 $0.32/lb
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Future (2025) Class Average Weights
EDAG Mass Saving Estimates
2015 Ford F-
150
Approximate Fuel
saving due to
Lightweighting
10%
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Future (2025) Class Average Weights
EDAG Mass Saving Estimates
Approximate Fuel
saving due to
Lightweighting
10%
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Thank you
The material in this presentation was possible with a lot of good feed back
from all participants
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Questions?
Harry Singh
Director Lightweighting
1 (248) 635-3174
harry.singh@edag-us.com
Eric McCarty
Auto/Steel Partnership
1 (248) 520 3009
emccarty@steel.org