a winner car body design development of the hyundai sonata.pdf
TRANSCRIPT
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w w w . a u t o s t e e l . o r g
A Winner: Car Body Design Development of the Hyundai Sonata
Carsten Hfer Hyundai Motor Europe Technical Center
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Background History Customer proposition Styling Practicality Performance Efficiency
Development process Platform strategy Weight optimization Stiffness Material Safety
Overview of Ulsan Plant Manufacturing strategy Flexible production system Productivity Quality
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
Product Concept
Background History Customer proposition Styling Practicality Efficiency
Development process Weight optimization Stiffness Material Safety
BiW Concept
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i40 intro.m4v
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Product Concept Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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Product Concept Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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7
2010 Sedan 2011 Sedan & Wagon
2004
1998
Product Concept Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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Product Concept BIW Concept /
Product Concept
Best in class roominess Class leading practicality
Sporty and emotional Modern interior
Target best in TCO Competitive pricing
3 USPs: rear seat reclining, auto defog, heated steering wheel
Best in class with 113g CO2/km
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
Product Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
Product Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept
Product Concept
Cargo capacity 19. 5 cu. ft. (553 liters) with the rear seats occupied Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down
Hyundai Sonata at GDIS Conference 2013
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Product Concept
0.32
0.29 0.30
0.29
Predecessor i40 Competition
Cd
8,013
8,878 8,840
Predecessor i40 Competition
10,082 22%
132
155 148
Predecessor i40 Competition
CO2 (g/km)
214
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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Product Concept BIW Concept /
BIW Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
SOP
SOP
-6 -4 -2
Full schedule predecessor 24M
Full schedule i40 18M
Model Fix
Design
Design Model Fix
Test
Test
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
Achieved a 7.6% reduction in BIW weight compared to predecessor.
438kg
Design concept Final drawings
456.3kg
Competition
438kg
EVI process
Design optimization -27.3kg
Hyundai Sonata at GDIS Conference 2013
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BIW Concept
Rearranging the part assembly allowed for a reduction of the material thickness From single part with uniform thickness to three parts with different, optimized thickness
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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BIW Concept
Change of the form from linear interior to radial interior lead to a material thickness reduction Divergence angle to improve airflow and NVH performance
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
Spare Member (0.8 ) Spare Member (1.0 )
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BIW Concept
Increased the torsional stiffness by 141% and the bending stiffness by 19%. Achieved 11% more torsional and 23% more bending stiffness compared to competition
0.32
24
14.6 0.29
Predecessor i40
28.6 35.3
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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Product Concept BIW Concept /
BIW Concept
Continuous members from engine room to rear floor in longitudinal direction Connections of floor, sides and roof form closed circular structures Main joints optimized by extensions and closed profiles
Hyundai Sonata at GDIS Conference 2013
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BIW Concept
The formation of a closed section connecting the underbody, cowl area and suspension strut improves the stiffness of the front-area This also increases the local stiffness of the suspension strut dome resulting in improved driving performance
+87%
Hyundai Sonata at GDIS Conference 2013
Product Concept BIW Concept /
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Product Concept BIW Concept /
BIW Concept
The vehicle rear end is reinforced by a double structure ring shape section The ring shapes are interconnected in longitudinal direction by the rear side members, waistline profiles and roof rails
+67%
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
The roof stiffness is increased by local extensions Optimized energy flow through maximized overlap Increased local stiffness through constant section profile
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
Application of 71m of structural adhesives leads to body stiffness increase of 14%
Hyundai Sonata at GDIS Conference 2013
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Product Concept
Hyundai i40 at Euro Car Body Conference 2011 BIW Concept
6.1 3.1 3.6
28.5
35.6
23.2
MS (120 280 MPa)
HSS (180 640 MPa)
AHSS (220 720 MPa)
UHSS (620 1280 MPa)
PHS (980 -1260 MPa)
Fibre reinforced plastic
Product Concept BIW Concept /
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
EuroNCAP comments: Driver knee airbag is standard equipment Maximum score for side barrier impact Bumper area scored maximum points for pedestrian protection Speed limitation assistance is standard equipment for best selling variant
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
20%
80%
20%
4%
12%
4%
14%
36%
30%
100%
89%
11%
24%
64%
12%
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
1 2
3
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept
1.3% 13.2%
16.3%
12.3%
12.6%
21.1%
12.0%
11.2%
Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept BIW Concept /
BIW Concept Hyundai Sonata at GDIS Conference 2013
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Product Concept Hyundai Sonata at GDIS Conference 2013 Hyundai Sonata at GDIS Conference 2013
Product Concept
World Car Concept Focused on local market customer demands Supporting Hyundais philosophy of Modern Premium Featuring Hyundais design language of Fluidic Sculpture
BiW Concept
Streamlined development process of 18 months CAE driven design for best performance and lowest cost Highly efficient use of High Strength Steels Excellent Light Weight Index to meet ecological demands Safe for Occupants and Pedestrians
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North American Light Vehicle Metallic Material Trends
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