ANALYSIS RESULTS SUMMARY:

Toyota Tundra 20% Front Seat

FMVSS 207/210 – April-06-05

Work Order: 233.41860.001.G

FEA Design Level #: 14
Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Template Revision: 1 Analyst (Employer): Ashish (Altair)
Revision Date: 01/01/05

April/06/05 1 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

I. Conclusions and Recommendations

Design 14 Iteration 22
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 23
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 24
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 25
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 27
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.

April-06-2005 2 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

I. Conclusions and Recommendations

Design 14 Iteration 28
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 29
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 30
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 75 msec bracket
supports right side buckles.
Design 14 Iteration 32
• The Toyota tundra 20% front seat buckles under the 207/210 load case. At 80 msec bracket
supports right side buckles.

April-06-2005 3 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description

Design Level 14 and Iteration 22

1) The design level 14 model was assembled from CAD data provided by JCI on
FEB/08/05.
Note: Bracket support outer side right side and Bracket support inner right side welding
increased as per design 11 iteration 19.

Welds added as per design11 iteration 19.

April-06-2005 4 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 23

From the design 14 Iter 22 model: following changes has been done
1) Welds are added as per design11 iteration 19 between bracket support inner right side
and tube cushion lateral reinforcement.

Hole size reduce to 24mm dia and Welds added as per design11 iteration 19.

April-06-2005 5 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 24
From the design 14 Iter 23 model: following changes has been done.
1)M10 bolt with no failure option used from bolt macro.

Design Level 14 and Iteration 25

From the design 14 Iter 23 model: following changes has been done.
1) M10 bolt with no failure option used from bolt macro.

April-06-2005 6 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 27

From the design 14 Iter 22 model: following changes has been done
1) 15mm weld added between bracket cushion support front and bracket support inner right side.
2) 15mm weld added between bracket cushion support front and bracket support outer right side.
3) CG loading chain shifted to center of the front CG bar.

15mm weld added between bracket 15mm weld added between bracket
cushion support front and bracket cushion support front and bracket
support inner right side. support outer right side.

April-06-2005 7 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 28

From the design 14 Iter 24 model: following changes has been done
1) 15mm weld added between bracket cushion support front and bracket support inner right side.
2) 15mm weld added between bracket cushion support front and bracket support outer right side.
3) CG loading chain shifted to center of the front CG bar.
4) Rear bolt head increased to 22mm to match with washer diameter.

15mm weld added between bracket 15mm weld added between bracket
cushion support front and bracket cushion support front and bracket
support inner right side. support outer right side.

April-06-2005 8 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 29

From the design 14 Iter 28 model: following changes has been done
1) Lap block change to center lap block.

Center Lap block used in design12 iteration 29 model

April-06-2005 9 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 30

From the design 14 Iter 29 model: following changes has been done
1) Welds are added as per design11 iteration 19 between bracket support inner right side and
tube cushion lateral reinforcement.

Hole size reduce to 24mm dia and Welds added as per design11 iteration 19.

April-06-2005 10 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

II. Design Level and Model Description …CONTD

Design Level 14 and Iteration 32

From the design 14 Iter 30 model: following changes has been done
1) Front welds between CG link and both side brackets are increase to 20mm. Rear welds
between CG link and both side brackets are increase to 36mm.
2) Rectangular slots on both side brackets filled.

~ 36mm weld

~ 20mm weld

April-06-2005 11 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

Design 14:

Welds between outer and inner RH cushion bracket

added as per design11 iteration 19.

April-06-2005 12 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Design 14 Iteration 22

Material and Thickness information for Major Components

April-06-2005 13 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 22

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 65msec and 140 msec and applied reaches 100% of the full
applied load reaches 91.5% of full load load.

April-06-2005 14 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 23

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and 140 msec and applied reaches 100% of the full
applied load reaches 98.9% of full load load.

April-06-2005 15 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 24

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 140 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.

April-06-2005 16 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 25

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 220 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.

April-06-2005 17 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 27

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 220 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.

April-06-2005 18 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 28

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 220 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.
April-06-2005 19 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 29

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 140 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.
April-06-2005 20 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 30

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 75msec and Buckled @ 140 msec and applied reaches 100% of
applied load reaches 98.9% of full load the full load.
April-06-2005 21 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

III. Detailed Analysis Results

Design 14 Iteration 32

Deformed Shape of Seat @ RH cushion Deformation plot with un-deformed geometry@

bracket buckling starts at 80msec and Buckled @ 140 msec and applied reaches 100% of
applied load reaches 100% of full load the full load.
April-06-2005 22 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 24

A = 33777.5 SR = 10577.6

LH cushion rear
A = 40104 SR = 15711

RH cushion front
A = 43035.5 SR = 7307.32
LH cushion front
A = 40660.4 SR = 4165.29

April-06-2005 23 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 25

A = 34101 SR = 11965

LH cushion rear
A = 38349 SR = 16446

RH cushion front
A = 43262.4 SR = 7538
LH cushion front
A =37618.4 SR = 4650

April-06-2005 24 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 28

A = 36023.2 SR = 9304

LH cushion rear
A = 53977 SR = 14281

RH cushion front
A = 47149.4 SR = 8357
LH cushion front
A = 41312 SR = 4466

April-06-2005 25 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 29

A = 36975 SR = 12203

LH cushion rear
A = 47200 SR = 13249

RH cushion front
A = 45536 SR = 7669
LH cushion front
A = 34891 SR = 5360

April-06-2005 26 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 30

A = 37376 SR = 9625

LH cushion rear
A = 48245 SR = 13289

RH cushion front
A = 47083.5 SR = 8008
LH cushion front
A = 33425.4 SR = 4107

April-06-2005 27 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 32

A = 36463 SR = 12663.4

LH cushion rear
A = 48957.4 SR = 13556.2

RH cushion front
A = 46956 SR = 7754.51
LH cushion front
A = 32522.3 SR = 3824.71

April-06-2005 28 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

IV. Test Set-up and Acceptance Criteria

Design 14 Iteration 22,23,24,25,27,28

Generic JCI shoulder

block
Belt exit point
Generic JCI shoulder clevis

Retractor
mounting point.
Generic JCI lap block

CG bars

Note: The “lap_e4152” is used for the center lap block

April-06-2005 29 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

IV. Test Set-up and Acceptance Criteria

Design 14 Iteration 29,30,31

Generic JCI shoulder

block
Belt exit point
Generic JCI shoulder clevis

Retractor
mounting point.
Generic JCI lap block

CG bars

Note: The “center lap block” is used for the center lap block

April-06-2005 30 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32

16200 N

4261 N

• Seatback in design position.

• Load levels shown are at FMVSS+ 20% (16200N). In the analysis, the applied
loads are held FMVSS + 20% load level.
• The shoulder and lap belt loading =13500x1.2=16200 N
• The CG loading =(20xgxmass)x1.2=(20x9.81x18.1 kg)x1.2=4261 N

Acceptance Criteria:
• Seat must hold FMVSS + 20% loads without any part fracture.

April-06-2005 31 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Design 14 Iteration 22,23,24,25,27,28

April-06-2005 32 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Design 14 Iteration 22,23,24,25,27,28

April-06-2005 33 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Design 14 Iteration 29,30,31

April-06-2005 34 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
Design 14 Iteration 29,30,31

April-06-2005 35 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 22,23,24,25,27,28,29,30,32
V. Analysis Methods Summary
The following standardized JCI methods were used for this analysis iteration(s):
Revision
JCI Analysis Method Comments/Exceptions
Level
207/210 General Analysis
1
Procedure (1/1/05)
(207210_Analysis_Procedure.pdf)

207/210 Body Block Positioning

Procedure 1
(1/1/05)
(Belt_Lengths_and_Body_Block_Positioning
_Procedure.pdf)

Dyna General Procedure 1

(Dyna_General.pdf) (1/1/05)

Forming Mapping Procedure 1

(Mapping_Forming_Results.pdf) (1/1/05)

Material Property Curves

0
(10/1/04)

Detailed Bolt Modeling Macro 2

(01/21/05)

April-06-2005 36 W.O. # 233.41860.001.G