Auto/Steel Partnership Lightweight Front End Structure Hydroform Solution and Cost Analysis

Sanjay Shah General Motors Corporation

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AUTO/STEEL PARTNERSHIP MEMBERS

John Catterall (GM) / Jody Shaw (USS) Project Leaders

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Background
Auto/Steel Partnership project on Lightweight Front End Structure using AHSS Motivation for using AHSS: - Mass avoidance - Adequate performance - Lower overall cost Phase I : Phase II : Optimize ULSAB design using AHSS Optimize Front Rail and Bumper system of 04 high volume production vehicle - Stamping Based - Hydroform Based
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Phase III :

Donor Vehicle Baseline Design

Components Steel Grade Weight

27 stampings BH210 & HSLA340 39.2 kg

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Phase II : LWB Stamped Solution

Components Steel Grade Mass Mass Savings

12 stampings DP780 30.5 kg 22.4%

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Hydroform based solution

Arent there enough problems in the world?

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Phase III : Hydroform Design Approach

- Use same approach for optimization of Front Rail and Bumper Beam using available packaging space as in Phase II - LWB Stamped design - Meet all the performance objectives 35 mph NCAP frontal crash, 40 mph IIHS frontal off-set crash, static stiffness and dynamic stiffness - Optimize design for mass by incrementally pushing manufacturing frontier (expanding knowledge) - Follow general tube hydroforming mfg. guidelines (% expansion, bend radius, corner radius etc..)

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Solstice Structure
Current State of Art for Hydroforming in production

DP590T, 1.8mm Hydroform Rails

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Hydroform Solution
Min bend radius to tube diameter ratio of 2.5

Max tube expansion 8%

Min corner radius to 10mm

Bumper - DP980 to Martensitic 1300 Hydroform DP600 to DP800 - Optimize using DoE for Gage and Grade
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Hydroform Solution
Bumper (Inner and Outer) Mart 1300 1.2mm Mart 1300 1.0mm Rail B DP800 1.3mm DP800 1.3mm

Tube Diameter (O.D.) = 108.6mm

Rail D DP800 2.0mm DP800 2.0mm Rail A DP800 1.2mm DP800 1.3mm

Rail C DP800 1.4mm DP600 1.4mm

Rail E DP800 1.4mm DP600 1.4mm

Rail F DP800 1.3mm DP600 1.3mm

Design 2 - Progressive Collapse Steel Grade DP800 Mass 28.8 kg Mass Savings 26.5%

Design 3 Non-Progressive Collapse Steel Grade DP600 and DP800 Mass 26.8 kg Mass Savings 31.8%

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Crash Simulation
35 mph full frontal NCAP Design 2

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35 mph NCAP
Design 2

SIMULATION RUN 35mph NCAP

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35 mph NCAP
Design 3

SIMULATION RUN 35 mph NCAP

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Crash Simulation Results

k

Crash Target Satisfied

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Stiffness Results
Stiffness Static Static Dynam ic Dynam ic Torsional Bending Torsional Bending (Nm /deg) (N/m m ) (Hz) (Hz) 21,002 20,482 20,454 12,639 12,399 12,387 21.1 24.8 24.9 24.4 26.3 26.4

Design Baseline Design 2 Design 3

Stiffness Target Satisfied

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Hydroform Solution - Mass Sensitivity

- Mass sensitivity of Bumper & Hydrof. Frt. Rail to mass of vehicle - By reducing mass of donor vehicle by 20%, additional mass savings of 12% to 18% in hydrof. rail & bumper system
Bum per (Inner and Outer) Hydroform Design Reduction Mass Option 2 M art 1300 1.0m m Design B =15.6kg Rail B DP600 1.4m m Rail D DP600 1.4m m Rail A DP800 1.0m m Rail C DP800 1.3m m Rail E DP600 1.3m m Rail F DP600 1.0m m

(39.8%)

Mass = 23.6 kg
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Manufacturing Frontier
Expanding Mfg. Systems with current challenges: - Tubes from AHSS (DP800 and DP600) - Tubes with D/t > 70 (thin wall tubing) - Tailored tubes (Soudronic, Mubea, Dofasco,
Thyssen-Krupp, Noble International, Corus etc.)

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Tailored Tube Solution

The main office sent us a microwave oven for our half-baked ideas.

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Flexible Rolling of Tailor Rolled Blanks

HSLA420 TRB flexible rolled 1.0 > 1.6 > 1.8 > 1.6 > 1.0 > 1.4 > 1.0
2,00

SheetWandstrke in mm mm metal thickness in

1,80 1,60 1,40 1,20 1,00 0,80 0,60 0,40 0,20 0,00 0 200 400 600 800 1000 1200 1400

tube length in mm Rohrlnge in mm

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Tailored Tubes

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Dofasco

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Volvo C70 A pillar Hydroform

Variable Wall and Diameter

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Manufacturing Frontier
Expanding Mfg. Systems with current challenges: - Tubes from AHSS (DP800 and DP600) - Tubes with D/t > 70 (thin wall tubing) - Tailored tubes (Soudronic, Mubea, Dofasco
Thyssen -Krupp, Noble International, Corus etc.)

- Hydroforming of AHSS, Tailored Tubes - Joining Methods for closed section parts
Arc welding, Laser welding, Single Sided Spot Welding, Projection Welding, Adhesive, Mechanical Fastening etc..

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Assembly
Components and Joining : MIG welding chosen as primary method

Tie Bar Extensions

Front & Rear Panel Skirt

Bumper Torque Box (not shown) Front Cradle Mount Rail

Rear Cradle Mount

Welding to floor (MIG or spot)

Stamped rail shown

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Components and Joining

Base
# of Weight (kg) Parts
Stampings Tailored Blanks Rollformings Hydroformings TOTAL 32 2 1 --35 30.77 5.36 6.39 --42.52

Stamped
# of Parts 14 6 ----20 Weight (kg) 12.75 18.90 ----31.65

Hydroform
# of Parts 10 ----2 12 Weight (kg) 8.25 ----20.60 28.85

Spot Welds MIG Welds (m) Bolts Rivets

796 0 .4 0 8 ---

675 0 .4 0 8 ---

143 9 .1 3 8 10

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Cost considerations

Do you want to be known as discoverer of fire or first man to pollute ?

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Cost Modeling Approach

Camanoe Associates
General Inputs
Accounting Data Fabrication & Assembly Process Data Material Prices Stamping Press Information Assembly Method Data

Body Calculations Stamping

Cost Breakdowns Process Data Process Data Predicted Line Description

Hydroforming
Cost Breakdowns

Production Volumes

Assembly
Costs for Each Joining Method

Body Inputs Stamping

Part Description Part Description Blanking Data Tube Data Stamping Data Hydroform Data Joining Methods Cost Summary By Hood Front End

Cost Results BodyResults

Cost Summary Stamping Cost per Part &per Process Summary by Part Assembly Summary per Subassy

Hydroforming Assembly
Subassembly List

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Total Cost
- Greenfield approach, Process based costing,, Dedicated Tooling cost, % Equipment Cost II
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III

At 225,000 units/year

Cost Analysis Dedicated Tooling Investment

Base Stampings Tailored Blank Stampings Rollformings Hydroformings Assembly TOTAL $12.5M $2.4M $0.2M --$4.4M $19.5M Stamped $7.8M $8.7M ----$4.1M $20.6M Hydroform $5.1M ----$5.1M $5.0M $15.2M

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Cost Analysis Variable and Fixed Cost

Base
Material Cost Other Variable Costs*
TOTAL VARIABLE COST
*Includes labor and energy

II
Stamped
$56 $46 $49 $54

III
Hydroform
$43 $39

$103
$48 $23 $40

$102
$40 $24 $37

$82
$65 $18 $40

Equipment Cost Tooling Cost Other Fixed Costs#

TOTAL FIXED COST
#Includes

$111 $214

$101 $203

$123 $205

building, maintenance, and overhead

TOTAL UNIT COST

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Detail report at http//www.a-sp.org

I know a web site that can help you

Everything these days is dot-com this and dot-net that! I cant stand it any more!!!

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Lightweight Front End Structure Hydroform based structure can provide mass and cost benefit

Thank You

Detail Report at http://www.a-sp.org

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