GDIS2017

Component Mass Study

Statistical Benchmarking

Benoit Singher, A2Mac1 Automotive Benchmarking

Russ Balzer, WorldAutoSteel

Donald Malen, University of Michigan

#GDIS | #SteelMatters 2

Statistical mass benchmarking

• Average of 25,000 photos available per vehicle

• Over 400,000 parts stored and available for further review

• Additional 25 new cars in North America, 20 in Europe, 12 in China, 12 in India are dissembled every year

• Programs available for Europe, North America, China, Thailand , India and coming soon for south America

• A database of over 500 vehicles fully disassembled

• Over 1100 parts reviewed per vehicle with data on mass, dimensions, materials, suppliers, coding, fasteners

#GDIS | #SteelMatters 3

Closures

Front door

Hood

Hatchback

Decklid

Liftgate

Chassis

Lower control

arm McP & SLA

Wheels

Front suspension

Rear suspension

15 Components analyzed

Body systems

Bumper beams

Front & Rear

Body structure

IP beam

Seat frame

Components Analyzed

#GDIS | #SteelMatters 4

May, 2010 2016

Automotive

Mass

Benchmarking

This report

January, 2014

History of studies using A2Mac1 database

#GDIS | #SteelMatters 5

2010 study 100 vehicles

23 25

17

30 35

13

This study 250 vehicles

46 51

70

56

29

22

39

2 5

12 16 17 16

12

0

10

20

30

40

50

60

70

80

1998 2000 2002 2004 2006 2008 2010 2012 2014

Number of vehicles

20

12

2020 2025

Analyze data in 5 year

increments to detect

trends

2016 Model year

Tear down count by model year

2014 study 200 vehicles

#GDIS | #SteelMatters 6

Distribution approximately uniform by model year

Heavily weighted to sedan and hatchbacks

Primarily Front wheel drive

Asia Europe NA Other Destination markets primarily NA & Europe

Attributes of vehicles in this study

#GDIS | #SteelMatters 7

Determine mass statistics for Aluminum and Steel unadjusted for mass drivers

Objectives

Create scatter plots of component mass vs significant mass driver

Stru

ctu

re M

ass

Area

Determine mass-driver equation for component mass to allow objective comparison

Steel if .0001

Alum if 670.0136.12

969.0AREAmSTRUCT

Identify efficient designs of each material and compare mass

Stru

ctu

re M

ass

Area

Identify material factor for each component

Steel Alum Mean 16.93 11.43 Std Dev 2.24 2.40 Count 240 21

For selected subsystems, compare Aluminum-to-Steel mass reduction for Structure and for System

Syst

em M

ass

Structure mass

MALUM/MSTEEL

Nominal Designs

Efficient Design

0.670 0.804

#GDIS | #SteelMatters 8

Best fit models

Power

Linear

m=b0 x1b1 x2

b2...

m=b0 +b1 x1+b2

x2

5 Define

subsystem

Propose mass drivers

Mass efficient designs

Mass driver

Sub system

Mass

6

mass efficient designs

Identify 0utliers Parity plot

Actual Mass

Estimated Mass

low mass

outliers

7 Compare mass

efficient designs

8

Data quality control

Extract data from website

A2Mac1

Extract subsystem mass & mass driver data

2 Mass statistics

Scatter plot analysis

3 1

Method

Regression process

4

#GDIS | #SteelMatters 9

Description of study and method Example: Body structure Key observations

Component Mass Study - Statistical Benchmarking

#GDIS | #SteelMatters 10

Body Structure: Raw data

2011-2015 Mean 308.8 Std Dev 21.3 Count 3

2011-2015 Mean 336.3 Std Dev 66.7 Count 208

2002-2015 Mean 331.5 Std Dev 63.8 Count 310

2002-2015 Mean 320.8 Std Dev 34.8 Count 6

2002-2010 Mean 321.7 Std Dev 56.5 Count 102

2002-2010 Mean 332.7 Std Dev 46.4 Count 3

354.6 55.5

4

0

100

200

300

400

500

600

2002 2004 2006 2008 2010 2012 2014 2016

Bo

dy

Str

uctu

re M

ass k

g

Model Year

Steel

0

100

200

300

400

500

600

2002 2004 2006 2008 2010 2012 2014 2016

Bo

dy

Str

uctu

re M

ass k

g

Model Year

Aluminum and Steel/Alum

Alum Steel CFRP/Alum Steel/Alum

#GDIS | #SteelMatters 11

Body Structure: Definitions

The body structure consists of the body-in-white with front sub-frame less doors including paint, sealer and mastic sound treatments. Vehicles with full frames have been excluded.

Gross Vehicle Mass

Plan View Area

Material

Mass drivers analyzed Structure

-Steel -Aluminum -Steel / Aluminum

#GDIS | #SteelMatters 12

Body Structure: Comparison with earlier data

2011-2015

Alum Steel

2002-2010

0

100

200

300

400

500

600

0 5 10 15

Bo

dy

Str

uctu

re M

ass k

g

Area m2

Body Structure Mass vs

Plan View Area

0

100

200

300

400

500

600

0 1000 2000 3000 4000

Bo

dy

Str

uctu

re M

ass k

g

GVM kg

Body Structure Mass vs

Gross vehicle mass

Alum Steel CFRP/Alum Steel/Alum

#GDIS | #SteelMatters 13

Mass-efficient designs were quantified by the number of standard errors, r, below the nominal. The criterion for choosing the number of standard errors below nominal, n, was at least three data samples were observed with mass equal to or less than that value.

R2 = 0.89, r=1.063

nSTEEL=1.090

nALUM=0.924

nST/AL=0.940

Steel1.000

St.Al0.917

Alum 0.652

AREAGVMmSTRUCT

416.0753.0448.0

0

100

200

300

400

500

600

0 5 10 15

Bo

dy

Str

uctu

re M

ass k

g

Area m2

Body Structure Mass

Steel1.000

St.Al0.917

Alum 0.652

nr

AREAGVMmSTRUCT

416.0753.0448.0

Steel nominal

efficient

Nominal

Efficient

Body Structure: 2011-2015 Regression Models

#GDIS | #SteelMatters 14

2010 study

2014 study R2=0.87, r=1.085

nSTEEL=1.050

nALUM=0.875

R2=0.83, r=1.094

nSTEEL=1.000

nALUM=0.914

AWD 1.08

RWD 1.00

FWD 1.02

Steel1.000

Alum 0.704AREAGVMmSTRUCT

599.0438.0418.3

Steel1.000

St.Al0.947

Alum 0.656

AREAGVMmSTRUCT

579.0546.0590.1

Current study

Body Structure: Comparison of studies R2 = 0.89, r=1.063

nSTEEL=1.090

nALUM=0.924

nST/AL=0.940

Steel1.000

St.Al0.917

Alum 0.652

AREAGVMmSTRUCT

416.0753.0448.0

Stru

ctu

re m

ass

kg

0

100

200

300

400

500

0 1000 2000 3000

2010 Study

0

100

200

300

400

500

0 1000 2000 3000

2014 Study

0

100

200

300

400

500

0 1000 2000 3000

Current Study Alum

Steel

Gross vehicle mass kg

Comparison of Efficient Designs Typical Area used for graphs

Stru

ctu

re m

ass

kg

Gross vehicle mass kg

Stru

ctu

re m

ass

kg

Gross vehicle mass kg

Alum

Steel

Alum

Steel

#GDIS | #SteelMatters 15

0

100

200

300

400

500

600

0 100 200 300 400 500 600

Actu

al M

ass k

g

Expected Mass kg

Body Structure: Examples of mass efficient designs Increasing

mass efficiency

Aluminum Body

2014 Land Rover

Mixed Aluminum/Steel Body

2014 Cadillac CTS

Alum Steel Steel/Alum

Steel Body

2013 VW Golf VII

#GDIS | #SteelMatters 16

Component Mass Study - Statistical Benchmarking

Description of study and method Examples Body structure Key observations

#GDIS | #SteelMatters 17

There is a considerable range of mass for steel components of the same size and function. Thus, there

is an opportunity in current production vehicles for mass reduction, even with the technology and

materials already in use.

0

100

200

300

400

500

600

0 5 10 15

Bo

dy

Str

uctu

re M

ass k

g

Area m2

Body Structure Mass

A=7.5 m2 Variability in structure mass of similarly sized components

A=7.5 m2

Possible opportunity for mass reduction using steel grades available now

Key Observations

#GDIS | #SteelMatters 18

When compared to an efficient steel design, the mass savings gap with aluminum significantly reduces.

Mass ratio greater for efficient designs

Mass Alum Mass Steel

Mass Alum Mass Steel

for efficient

designs

Key Observations

#GDIS | #SteelMatters 19

Mass saving achieved in the structure due to material substitution is often not realized at the system level.

Mass reduction from aluminum structure not fully carried over to system mass reduction

Key Observations

#GDIS | #SteelMatters 20

For More Information

Benoit Singher

A2Mac1 Automotive Benchmarking

(1) 734 973 6468

bsingher@a2mac1.us