S-in motion Mid-size Sedan and SUV/media/Files/Autosteel/Great Designs in Steel... · S-in motion® Mid-size Sedan and SUV The Solution – ®S-in motion Mid-size Sedan and SUV •

S-in motion® Mid-size Sedan and SUV

The Challenge

• To date, all light steel vehicle solutions have targeted

individual vehicles.

• Light vehicle OEM’s today don’t build one-off vehicles

– they use PLATFORMS that include many vehicle

styles and powertrain options.

• Steel solutions for individual vehicles, therefore, are

of limited value.

2


The Solution – S-in motion® Mid-size Sedan and SUV

• A catalogue of steel solutions for a mid-size

PLATFORM that includes both a sedan and a SUV.

• Solutions provide impressive weight reduction.

• At an affordable light weighting cost.

• Meeting all pertinent safety and performance

requirements.

3

S-in motion® Mid-size Objective

Validated loadcases: stiffness and crash requirements including IIHS frontal

small overlap rigid barrier, roof crush, side MDB, side pole as well as FMVSS301

rear crash tests.

S-in motion® Midsize is a catalog of lightweight solutions for Midsize vehicles.

Sedan: 385 kg Sedan: 300 kg

Baseline: NA market representative

Mid-size vehicle

Scope: BIW + Bumpers + door in white

Objective: achieve a 20% weight

reduction at very low cost difference

thanks to advanced high strength steels

SUV: 522 kg SUV: 420 kg

Roof Crush 40% Frontal 25% Frontal Side MDB Side Pole Rear

4

ArcelorMittal products used in this project

ArcelorMittal currently available grades

Essentially AHSS grades

• Dual Phase family

• Complex Phase family

• Usibor®1500

• Laser welded blanks

(especially Usibor®1500

/Ductibor®500)

• MartINsite® family up to

MartINsite® 1700

And also

• DP490 Exposed

ArcelorMittal emerging grades portfolio

• New hot-stamping grades Usibor®2000, Ductibor®1000

• High formability grades Fortiform® 980 and 1180 (980HF, 1180HF)

• MartINsite® 2000

Tensile strength values

2 sets of solutions: one with current grades, one with emerging grades

5

NA Mid-size Sedan Benchmarking

Benchmarked vehicles represent

60% of 2013 US Mid-size sales

(5 of top 6 sellers)

Source:

Fusion Accord Malibu Camry Altima

6

NA Mid-size Sedan Benchmark & Solutions

7

NA Mid-size sedans

BIW weight without CMS* vs Curb Weight

Aluminum intensive BIW

Vehicle curb weight (kg)

BiW

weig

ht

(kg)

(note: no secondary mass savings were considered for the solution vehicles)

The proposed BIW solutions are very close to aluminum intensive BIW.

S-in motion® Mid-size Sedan baseline

S-in motion®

Mid-size solutions

Source:

* CMS = Crash Management System

(bumper beam and crash boxes)

NA Mid-size Sedan Benchmark & Baseline

Honda Accord SOP 2012 Nissan Altima SOP 2012

S-in motion® Mid-size

Sedan baseline BIW

material breakdown

35% AHSS

+ PHS

Ford Fusion SOP 2013

Source:

Baseline is in line with current NA Mid-size Sedan BIWs (35% AHSS + PHS).

Benchmarked material breakdown values are based on A2Mac1 material analysis

8


33% AHSS

+ PHS 31% AHSS

+ PHS

39% AHSS

+ PHS

NA Mid-size SUV Benchmark & Solutions

The proposed BIW solution weight is close to aluminum intensive SUV BIW.

Explorer (4x2)

2011 Grand Cherokee

(4x4) 2014

Traverse (4x4)

2011 Highlander (4x4)

2013 Pilot

Pathfinder (4x4)

2014

Source:

NA Mid-size SUV BIWs

9

BiW

we

igh

t (k

g)

Footprint (m2)

PHS intensive luxury SUV

Aluminum intensive luxury SUV

SUV baseline

S-in motion® Mid-size SUV solution

Baseline SUV Representation: BIW+CMS*

Mid-size SUV Baseline

The S-in motion® Baseline considers the increase in AHSS use between 2010 and 2015

and therefore represents current state of the art (33% AHSS + PHS + MS).

SOA 2015:

33% AHSS + PHS + MS

Ford Explorer

SOP 2010

Jeep Grand Cherokee

SOP 2010

10

16% AHSS

+ PHS + MS

8% AHSS +

PHS + MS

* CMS = Crash Management System

(bumper beam and crash boxes)

Mid-size Sedan / SUV Platform

S-in motion® Mid-size SUV Guidelines

• Modular approach in regard to the Mid-

size Sedan

• Type of body: unibody

• Worst case for transmission choice in

one model:

o No prop-shaft present for a more

severe intrusions scenario

o 4x4 transmission mass considered

25% of underbody mass of the SUV Solution is carried

over from the Sedan Solution underbody [86 / 241 parts]

Transparent white:

specific SUV parts

Green:

100% Sedan C/O

Blue:

Scaled Sedan parts

(wheelbase + 90mm)

S-in motion® Mid-size SUV S-in motion® Mid-size Sedan

The S-in motion® Mid-size SUV model was built as a platform extension

of the S-in motion® Mid-size Sedan.

11

Bandwidth study on 200 kg heavier vehicle

A typical Midsize bandwidth is about 200 kg

comparing lightest I4 FWD to PHEV or AWD version Mass was added on engine and rear structure of S-in motion®

Mid-size Sedan FEM to simulate heaviest vehicle

Baseline

Solution +200 kg

Solution +200kg

Performances on major crash load cases are restored with local reinforcements (+3.7 kg).

No reinforcement required

to meet performance target

Usibor®1500 patch blanks up-

gauged or extended New side sill reinforcements

Cross-member

patch blank

extended

Shotgun

thickness

increased

No reinforcement required

to meet performance target

Roof crush +0.2 kg

SORB +3.5 kg

REAR SIDE

Maximum plastic strain of 9%

in fuel tank (target <15%)

Max level 4.0 UVW B-pillar safety space 18.8 cm

from seat centerline

Per vehicle Per vehicle

+ 150 kg in rear (battery)

+ 50 kg on

engine

Powertrain variants

Curb

weight

12

Baseline

Solution +200 kg

S-in motion® Mid-size Sedan

Cost assessment - current grades

The proposed design is about $1/ kg saved higher on cost.

Hypothesis:

• amortization over 5 years

• 300,000 vehicles per year 100% 107%

46%

15%

35%

4%

49%

15%

32%

4%

13

Baseline S-in motion® Mid-size Sedan

Sedan Current Steel Grades Solution

Component Total Mass Mass savings

Vehicle weight 1391.8 kg 6%

BIW+CMS 248.2 kg 24%

Front Doors 14.1 kg (x2) 15%

Rear Doors 11.2 kg (x2) 19%

Total 298.8 kg 23%

Baseline Representative of NA Market, Mid-size vehicle

Current Grades Solution


86 kg weight reduction

56%

AHSS

(Scope: BIW + CMS + DIW)

14

Component Total Mass

Vehicle weight 1478.2 kg

BIW+CMS 324.4 kg

Front Doors 16.5 kg (x2)

Rear Doors 13.9 kg (x2)

Total 385.2 kg

42%

AHSS

Sedan Emerging Steel Grades Solution


Vehicle weight 1378.0 kg 7%

BIW+CMS 234.5 kg 28%

Front Doors 14.1 kg (x2) 15%

Rear Doors 11.2 kg (x2) 19%

Total 285.1 kg 26%




15


Vehicle weight 1478.2 kg

BIW+CMS 324.4 kg

Front Doors 16.5 kg (x2)

Rear Doors 13.9 kg (x2)

Total 385.2 kg

Emerging Grades Solution

59%

AHSS


42%

AHSS

SUV Current Steel Grades Solution


Vehicle weight 1944 kg 5%

BIW+CMS 359 kg 19%

Front Doors 16 kg (x2) 20%

Rear Doors 15 kg (x2) 17%

Total 420 kg 20%


Current Grades Solution


42%

AHSS


16


Vehicle weight 2046 kg

BIW+CMS 445 kg

Front Doors 20 kg (x2)

Rear Doors 18 kg (x2)

Total 522 kg

33%

AHSS

53%

AHSS


SUV Emerging Steel Grades Solution


Vehicle weight 1934 kg 5%

BIW+CMS 349 kg 21%

Front Doors 16 kg (x2) 20%

Rear Doors 15 kg (x2) 17%

Total 410 kg 21%


Emerging Grades Solution


42%

AHSS


17


Vehicle weight 2046 kg

BIW+CMS 445 kg

Front Doors 20 kg (x2)

Rear Doors 18 kg (x2)

Total 522 kg

33%

AHSS


51%

AHSS

DESIGN HIGHLIGHTS


18

Sedan Current Steel Grades Breakdown

Usibor®1500 – 80.9 kg

PHS > 450MPa - 7.8 kg

MartINsite®1700 – 11.7 kg

DP980 – 9.6 kg DP590 - 15.4 kg

DP490 exposed – 8.5 kg

HSS – 37.9 kg

Mild Steel - 71.1 kg

DP780 and HR780FC – 5.5 kg

Tensile

strength

values

19

Sedan Emerging Steel Grades Breakdown

20

Tensile

strength

values

Ductibor® 1000 - 17.4 kg

MartINsite®2000 and 1700 – 11.7 kg

Fortiform®1180 and

DP1180 – 6.4 kg DP780 and HR780 - 3.1 kg

DP490 exposed – 7.9 kg

HSS – 34.2 kg

Mild Steel - 60.8 kg

Fortiform®980 and DP980 – 10.3 kg

Usibor®2000 – 62.6 kg Usibor®1500 – 20.2 kg

SUV Current Steel Grades Breakdown

Usibor® 1500 – 98 kg

Ductibor® 500 – 12 kg

MartINsite® 1700 – 11 kg

DP980 – 38 kg DP780 – 2 kg DP590 – 14 kg

DP490 exposed – 15 kg

HSS – 38 kg

Mild Steel – 131 kg

Tensile

strength

values

21

SUV Emerging Steel Grades Breakdown

Usibor® 2000 – 53 kg Ductibor® 1000 – 13 kg

MartINsite® 1700 – 11 kg

Fortiform® 1180 – 15 kg DP780 – 2 kg

DP490 exposed – 15 kg

HSS – 38 kg

Mild Steel – 131 kg Usibor® 1500 – 43 kg

Fortiform® 980 – 26 kg

Ductibor® 500 – 2 kg

Tensile

strength

values

22

SUV Front Structure

23

Module weight : 88 kg

The solution is 12 kg lighter and meets Small Overlap Rigid Barrier Crash requirement

Small Overlap Rigid Barrier crash rating :

Marginal, with a high risk of “Poor”

downrating due to the leg entrapment

M Small Overlap Rigid Barrier crash rating :

Good G

Solution Module weight : 76 kg

Mass savings : 12 kg (13%) Baseline

Highlight: Small Overlap Test

24

The bumper extension and strut

required for a Midsize SUV

S-in motion® Midsize Sedan

S-in motion® Midsize SUV

Strong body side is essential for ‘Good’ rating

Achieved with Usibor ® / Ductibor ®

BASELINE

SOLUTION

Highlight: Laser Welded Shotgun

25

25

Full front US NCAP

Energy

absorption

IIHS Small Overlap

Front Mid Rear

Energ

y

Energ

y (k

J)

DP590 front

soft absorption

zone

DP980 rear

absorption

zone

Dual phase LWB shotgun

Front Mid Rear

Energ

y

Energy

absorption

SUV Front Structure – Rails

26

LWB DP590

1.9 / 2.2

LWB HR340LA

1.7 / 1.9

LWB

DP590 1.4 /

DP980 1.6

LWB

DP590 1.4 /

DP980 1.5

DP980

1.3 mm

SUV Front Structure – Shotgun

27

LWB

DP590 1.3 / DP980 1.3

/ DP980 1.4

LWB

DP590 0.9 / DP980 0.9

/ DP980 1.0

DP780

1.25

DP780

1.6 DP780

1.6

SUV Front Structure – Bumper

28

HR340LA

2.5 mm

HR340LA

2.0 mm

MartINsite®1500

1.5 mm MartINsite®1700

1.4 mm

MartINsite®1500

0.8 mm

DP590

1.4 mm

DP980

1.3 mm

DP590

1.3 mm

DP980

1.4 mm

SUV Bodyside Structure – Door Ring Outer

29

Inr + Otr: 57 kg per side

34 kg per vehicle can be saved thanks to AHSS, PHS and laser welded blank solutions.

Baseline Solution Module weight: 40 kg per side

Mass savings: 17 kg (30%)

LWB Door-ring

Usibor® 1500 / Ductibor® 500

CR380LA

Usibor® 1500

DP980

DP980

DP590

DP980

1.3

1.7

1.6

1.4

1.6

1.3

0.8

1.0

DP980

1.4

SUV Bodyside Structure – Inner

30

DP780

Usibor® 1500

CR340LA

CR340LA

DP590

DP590

MartINsite® 1300

LWB Usibor® 1500

1.5 / 1.2 / 1.3

LWB Usibor® 1500

0.7 / 1.4 / 0.7

LWB Usibor® 1500

1.7 Usibor® 1500

1.0

Usibor® 1500

0.9

DP980

1.3

DP980 1.3

DP980 1.3

DP980

0.9

DP980 1.2

DP980 1.1

DP980 1.4

34 kg per vehicle can be saved thanks to AHSS, PHS and laser welded blank solutions.

Inr + Otr: 57 kg per side Baseline Solution Module weight: 40 kg per side


Highlight: Usibor®1500 LWB B-pillar Inner

31

Baseline A and B

inner pillars 13 kg

The Usibor® 1500 laser welded B-pillar inner ensures required roof strength

without a supplementary inner reinforcement.

9 kg

Solution A and B

inner pillars

Usibor®

1500

All parts CR340LA, except for

the inner B-pillar reinforcement.

Usibor® 1500

0.7 mm

Usibor® 1500

0.7 mm

Usibor® 1500

1.4 mm

All parts Usibor® 1500

Laser Welded Blanks

SUV Floor Structure

32

Baseline Solution Module weight: 61 kg

Module weight: 45 kg


16 kg mass savings are reached thanks to the intensive use of Usibor® 1500

and press hardened steels Laser Welded Blanks.

DP590

2.0

DP590 1.6

DP590 2.1

Usibor®

1500

1.2 LWB Usibor® 1500

1.5 / 0.85

LWB Usibor® 1500

1.7 / 1.9 / 1.7 / 0.9

LWB

Usibor® 1500 1.1 /

Ductibor® 500 1.4

Usibor® 1500

1.2

Usibor® 1500

1.4

LWB

Usibor® 1500 1.3 /

Ductibor® 500 1.6

Usibor® 1500

1.2

DP600 1.5

CR380LA 1.6

DP980

1.3

DP980

1.3

Highlight: Hot Stamped LWB Cross Member

33

Usibor® 1500 and Ductibor® 500 Laser Welded Blanks with Usibor® 1500 tunnel

reinforcement are efficient solutions for side pole crash tests.

5th percentile pole 50th percentile pole

SOLUTION

Ductibor® 500

Usibor® 1500

Anti-intrusion

Energy

Absorption

SUV Rear structure

34

Baseline Solution Module weight : 59 kg Module weight: 45 kg


14 kg mass savings using press hardening grades for the rear crash load path.

CR340LA

1.5

HR420LA

2.0

HR420LA

1.95

HR340LA

1.8

CR270LA

0.9

CR340LA

1.5

CR340LA

1.5

CR3 0.9

LWB

Usibor® 1500 1.7

Usibor® 1500 1.7 (HT700)

Ductibor® 500 1.6

Usibor® 1500

0.95

LWB Usibor®

1500

0.9 / 0.7 / 0.9

LWB CR3

0.6 / 0.9 / 0.6

Usibor® 1500

0.9

MartINsite®

1700

1.4

HR340LA

1.9

Highlight: Hot Stamped LWB Rear Rail

35

Hot stamped Laser Welded Blank Rear Rail solution is very effective to meet high speed

rear crash requirement.

Usibor® 1500 1.7 mm or

Usibor® 2000 1.6 mm to

preserve fuel tank integrity

1.7mm Usibor® 1500 partly heat

treated (HT700) or Ductibor® 1000

to manage plastic hinge

Ductibor® 500 1.6 mm or Ductibor® 1000 1.4 mm

with triggers to absorb as much energy as possible

Rear crash FMVSS301

deformable barrier at 80 km per hour

Baseline Solution

Max. value

7.1% Max. value

4.8%

Fuel tank plastic strain

SUV Current Grade – BIW Stiffness

36

Load case Load Target Baseline Solution Performance

Torsion

Fz=±844N in

front shock

towers

≥ 20 kNm/º 23.5

kNm/º

22.9

kNm/º

Bending Fz=-4000N on

seat fixations ≥ 10 kN/mm

9.8

kN/mm

13.8

kN/mm

1st Torsion

Mode

Lanczos

Method

Free free

Extraction of

20 modes

1st

EigenMode ≥

37 Hz

40 Hz 40 Hz

1st

Bending

Mode

1st

EigenMode ≥

37 Hz

48 Hz 48 Hz

Solution meets all global stiffness targets thanks to additional stiffening parts, as

well as gauge and adhesive optimization.

OK

Close

to

target

Below

target

SUV Current Grade – Crash Performance

37

Solution meets all targets and exceeds baseline performance.

Crash test Target Baseline Solution Performance

Front 100% TTZ > 70 ms

Pulse < 30 g

74 ms

26 g

80 ms

23 g

Small Overlap

25% Intrusion in green area Marginal Good

ODB 40% Intrusion in green area Good Good

IIHS MDB

Side

Intrusion safety > 12.5

cm 18 cm 20 cm

FMVSS 214

Pole Intrusion safety > 0 mm

5th p: 1 mm

50th p: -19 mm

5th p: 74 mm

50th p: 55 mm

FMVSS 301

Rear

< 15% plastic strain on

fuel tank 7% 5%

IIHS Roof

Crush

>4.4 Unloaded Vehicle

Weight (UVW) 5.1 x UVW 4.9 x UVW

OK

Close

to

target

Below

target

Stamping analysis studies

All concepts are feasible with a few minor geometry changes on initial design

Stamping analysis carried out on challenging applications:

• laser welded blanks

• hot stamped parts

• thin gauge parts

38

Conclusions

1. ArcelorMittal solutions have reduced the weight of the baseline by 86 kg

(23%) for the Sedan and 102 kg (20%) for the SUV with steel grades

commercially available today.

2. Additional weight savings of 14 kg (26% total weight reduction) for the

Sedan and 10 kg (21% total) for the SUV can be achieved with steel

grades that will be commercially available from ArcelorMittal within less

than two years.

3. Weight savings achieved for large bandwidth, multi-vehicle platform.

4. These solutions can be implemented with only a small cost increase.

5. S-in motion® Mid-size Sedan and SUV solutions can be adapted to

OEM’s specific designs and requirements through co-engineering

projects.

39

Acknowledgements

• The S-in motion® Mid-size Sedan and SUV engineering design

projects were led by Ivan Viaux (Sedan) and Florin Arnautu (SUV)

from ArcelorMittal’s automotive R&D lab in Montataire, France. Ivan

and Florin also developed the content for this presentation.

• Contract engineering services were provided by Altair Engineering

for the sedan project, and by Magna Steyr for the SUV project.

40

Documents

S-in motion Mid-size Sedan and SUV/media/Files/Autosteel/Great Designs in Steel... · S-in motion® Mid-size Sedan and SUV The Solution – ®S-in motion Mid-size Sedan and SUV •