advanced high -strength steel technologies in the 2017 .../media/files/autosteel/great... ·...
TRANSCRIPT
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GDIS2017 ©2016-17 FCA US LLC
Advanced High-Strength Steel Technologies in the 2017 Chrysler Pacifica Jeff Tibbenham & James Truskin Fiat Chrysler Automobiles US LLC
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#GDIS | #SteelMatters 2 ©2016-17 FCA US LLC
The First 5 Generations…
H E R I TA G E
The 1st - 1984 1991-1995 1996-2000 2001-2007 2008-2016
6M CUR R E NT O WN E R S
13 .5M+ UN I TS S O LD
14 CO N S E CUT I VE YE A R S
H I GHE S T LO YA LTY
3 A WA R DS
JD PO WE R I Q S
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#GDIS | #SteelMatters 3 ©2016-17 FCA US LLC
Chrysler Pacifica
©2016-17 FCA US LLC
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#GDIS | #SteelMatters 4 ©2016-17 FCA US LLC
Exterior Styling
©2016-17 FCA US LLC
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#GDIS | #SteelMatters 5 ©2016-17 FCA US LLC
2017 PACIFICA Final Design
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#GDIS | #SteelMatters 6 ©2016-17 FCA US LLC
Roof Options: 2 Cd: 0.3 Passengers: 8 Luxuriously crafted interior
Design Features
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#GDIS | #SteelMatters 7 ©2016-17 FCA US LLC
Industry Leading
• 10” Seatback Touch Screens In 2nd Row
• Blu-Ray DVD • Wireless & HDMI
Device Connectivity • 7” TFT Instrument
Cluster
Technology & Entertainment
Modern & Stylish
• Tri-pane Vista View Sunroof
• 20” Wheels • LED Accent Lighting • Rotary Style E-Shift
Design
Comprehensive Feature Suite
• ParkView® Rear Backup Camera
• Surround View Camera • Forward Collision
Warning • Adaptive Cruise Control • LaneSense® Lane
Departure Warning • ParkSense®
Parallel/Perpendicular Park Assist With Stop
• KeySense™ Programmable Key Fob
Safety & Security
Efficient
• Hybrid Technology • Hands Free Sliding
Doors & Liftgate • Easy Tilt 2nd row Seats
w/Child Seat Preserve • Stow ‘n Vac™
Integrated Vacuum • Capless Fuel Fill • Push-Button Sliding
Doors • Keyless Enter ‘n Go™
Passive Entry / Push Button Start
Fuel Economy & Convenience
Multi-functional
• 8 Passenger Seating with Stow n’ Go®
• Stow n’ Go Assist® • Heated & Ventilated
Seats • Heated Steering Wheel • Power 3rd Row
Versatility & Comfort
Pacifica - “Why Buy” Pillars
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#GDIS | #SteelMatters 8 ©2016-17 FCA US LLC
All New Hybrid Technology Most versatile and functional of
any Hybrid in the market
Innovative Package Battery in center of vehicle
• No compromise to cargo objectives • Neutral handling effects
Class-Leading Performance
PHEV Capability
2h r s CHARGE TIME
33mi le BATTERY RANGE
84 CITY EMPG
16kWh BATTERY
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©2016-17 FCA US LLC #GDIS | #SteelMatters 9
©2016-17 FCA US LLC
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#GDIS | #SteelMatters 10 ©2016-17 FCA US LLC
Challenges: Pacifica BIW Design
Quietist/Best Handling Minivan • Structural Rigidity & Isolation • Local Stiffness
• IIHS TSP+ (incl. GOOD SORB rating) • 5* NCAP • FMVSS Regulations
• 8 Passenger Seating • 2nd Row Width • 4’x8’ Plywood
• >10% Mass Reduction • Increased functional objectives
• Current model & Pacifica
manufactured on same line
• Minimize Downtime
• Protect Interior Space • Common Body Structure
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#GDIS | #SteelMatters 11 ©2016-17 FCA US LLC
Engineering Development Process Voice of the Customer
Vehicle-Level Functional Objectives
Body System Functional Objectives
• Joints • Load Paths
• Sections • Materials
Design Execution Rapid Concept Development (RCD)
FCA toolset and strategic approach to BIW structure development
Faster concept → CAE assessment loop
Increased number of assessed concepts
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#GDIS | #SteelMatters 12 ©2016-17 FCA US LLC
Rapid Concept Development (RCD) Process CAE ANALYSIS
Concept 2…
Concept 1
New Section Proposals
Benchmarking & Topology Optimization
OPTIMIZATION • Thousands of optimization runs • Structural knowledge building • Early mass reduction initiative
NEW RCD Baseline Model
JOINT STIFFNESS ASSESSMENT
Surrogate Geometry New Package
New Theme Detailed Design Material Selection
DESIGN DEVELOPMENT
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#GDIS | #SteelMatters 13 ©2016-17 FCA US LLC
Load Path Concept Generation
Topology Optimization Production Design
Load Path Optimization • Critical activity for efficient use of material • Optimized structure around key packaging hard
points
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#GDIS | #SteelMatters 14 ©2016-17 FCA US LLC
Pacifica BIW Design Optimization Tools
Panel Bead Optimization (Local Stiffness,
Mobilities)
Global Topology Optimization (Loadpaths)
Sub-System & Component Topology Optimization
(Efficiency)
Weld/Adhesive Optimization
Multi-Disciplinary Optimization – MDO
(Weight, Attribute Balancing)
Joint & Section Optimization
(Continuity)
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#GDIS | #SteelMatters 15 ©2016-17 FCA US LLC
Weight Reduction Breakdown
“Pacifica Minivan lost 250 pounds [113kg].” - Detroit Free Press – Sunday, March 20, 2016
“At 4,315 pounds [1876kg], the new Pacifica is 250 pounds [113kg] lighter than the outgoing Chrysler Town & Country and is the lightest minivan on the road…” - Detroit Free Press – Sunday, March 20, 2016
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#GDIS | #SteelMatters 16 ©2016-17 FCA US LLC
Weight Reduction Breakdown
-13% (76kg) TOTAL BODY SYSTEM WEGHT REDUCTION
- 2 2 % CLOSURES
- 1 2 % BIW
-11% FEM + BUMPERS
512 kg 452 kg
64 kg 50 kg
28 kg 25 kg
0100200300400500600
Syst
em W
eigh
t (kg
)
FEM & BumpersClosuresBIW
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#GDIS | #SteelMatters 17 ©2016-17 FCA US LLC
BIW Materials: Mild Steel Applications
Mild Steel <210 MPa YS (115kg)
25.4%
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#GDIS | #SteelMatters 18 ©2016-17 FCA US LLC
BIW Materials: HSS Applications
HS Steel >210 MPa YS (102kg) 22.6%
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#GDIS | #SteelMatters 19 ©2016-17 FCA US LLC
BIW Materials: AHSS Applications
AHS Steel DP590 TRIP690 (135kg)29.9%
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#GDIS | #SteelMatters 20 ©2016-17 FCA US LLC
BIW Materials: UHSS Applications
AHS Steel+ DP780 (37kg) 8.2%
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#GDIS | #SteelMatters 21 ©2016-17 FCA US LLC
Hydroformed Upper Load Beam
• (2) DP780 Hydroformed tubes • Optimized strength, stiffness and load path
requirements around tight packaging
1.8 kg Saved per Vehicle
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#GDIS | #SteelMatters 22 ©2016-17 FCA US LLC
BIW Materials: Press Hardened Steel (PHS)
Press Hardened Steel PHS1300, PQS550
(50kg) 11.1%
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#GDIS | #SteelMatters 23 ©2016-17 FCA US LLC
Front Door Ring Strategy
• 5-piece, multi material welded blank • Eliminated insert and assembly operations • Weight = 13.7kg per side
10kg saved per vehicle
1.6mm PHS1300
1.3mm PHS1300
2.0mm PHS1300
1.6mm PQS550
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#GDIS | #SteelMatters 24 ©2016-17 FCA US LLC
Component Testing and Validation
B-Pillar Component Simulation Model
B-Pillar Component Validation Test
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#GDIS | #SteelMatters 25 ©2016-17 FCA US LLC
BIW Materials: Plastic Structural Inserts and Baffles
Plastic Structural Inserts & Baffles (2kg) 0.4%
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#GDIS | #SteelMatters 26 ©2016-17 FCA US LLC
BIW Materials: Other – Metal–Plastic–Metal Laminates (NVH)
Other NVH Steel (11kg) 2.4%
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#GDIS | #SteelMatters 27 ©2016-17 FCA US LLC
BIW Materials Strategy
Mild Steel <210 MPa YS
(115kg) 25.4%
HS Steel >210 MPa YS
(102kg) 22.6%
AHS Steel DP590 TRIP690 (135kg) 29.9%
AHS Steel+ DP780
(37kg) 8.2%
Hot Stamp PHS1300, PQS550
(50kg) 11.1%
Plastic Structural Inserts
(2kg) 0.4%
Other, NVH Steel
(11kg) 2.4%
7 2 % H S S 2017 PACIF ICA
1 2 STEEL GRADES
5 0 % H S S 2016 TOWN &
COUNTRY
9 5 0 M P a MAX Y IELD STRENGTH
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#GDIS | #SteelMatters 28 ©2016-17 FCA US LLC
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#GDIS | #SteelMatters 29 ©2016-17 FCA US LLC
Impact Development
NHTSA RATING
TARGET
> 8 5 0 0 CAE SIMULATIONS
T S P + I IHS RATING
TARGET
REGULATORY 3rd PARTY (IIHS)
> 8 0 FULL VEHICLE IMPACT TESTS
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#GDIS | #SteelMatters 30 ©2016-17 FCA US LLC
Frontal Impact Load Paths
Dual Impact Load Path Strategy • AHSS Front Rails (70%) • AHSS Front Cradle (30%)
• Engineered detach of front cradle rear mount for increased crush space
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#GDIS | #SteelMatters 31 ©2016-17 FCA US LLC
SORB Impact Load Paths
Offensive and Defensive Structure • Body and Chassis systems work
together early in the event • AHSS Safety cage reduces passenger
compartment intrusions
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#GDIS | #SteelMatters 32 ©2016-17 FCA US LLC
SORB Impact Load Paths Offensive Enablers • Early engagement of body rail and chassis structure initiate
lateral movement away from barrier • Integrated bumper and UHSS Load beam system
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#GDIS | #SteelMatters 33 ©2016-17 FCA US LLC
SORB Impact Load Paths Defensive Enablers • AHSS/UHSS-Reinforced Safety Cage
• TWB Press Hardened door ring • Strategic flange conditions for welds in shear and
compression loading
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#GDIS | #SteelMatters 34 ©2016-17 FCA US LLC
Rear Impacts Load Paths
AHSS/UHSS Rear Rail Assembly • Optimized rear rail topology and suspension
design for improved load path continuity and suspension clearance
• Optimized lateral bending mode of DP590 Rear Rail for efficient energy absorption
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#GDIS | #SteelMatters 35 ©2016-17 FCA US LLC
FMVSS 216a Load Paths
UHSS Safety Cage • Press Hardened, integral A-Plr and B-Plr reinforcements • Press hardened roof bow and front header for load
transfer • Load achieved: >4.5 x GVW
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#GDIS | #SteelMatters 36 ©2016-17 FCA US LLC
Safety Performance Summary
www.iihs.org
2017 Chrysler Pacifica Minivan
Crashworthiness Small overlap front Moderate overlap front Side Roof strength Head restraints & seats
G G G G G
With optional equipment
CRASH AVOIDANCE & MITIGATION
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#GDIS | #SteelMatters 37 ©2016-17 FCA US LLC
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#GDIS | #SteelMatters 38 ©2016-17 FCA US LLC
NVH – Torsion Mode
Multi-Ring Body Structure Concept • Front End Module • +Shock Tower / Plenum / Cradle • B-Plr / C-Plr / D-Plr
D-Ring Structure Optimization • Structural insert in Upper D-Plr
• +1.3 Hz and 2.7 kg saved per vehicle • Improved shake performance
26.9 29.2 30.5
24
26
28
30
32
Town & Country PACIFICA w/oD-Plr Inserts
PACIFICAFr
eque
ncy
(Hz)
1st BIW Torsion Mode
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#GDIS | #SteelMatters 39 ©2016-17 FCA US LLC
Competitive Body Torsional Stiffness
Lightweight Index Body in White Mass (kg)
Area (m2) x Torsional Stiffness (kN-m/deg)
12.2
22.9
0
5
10
15
20
25
Town & Country PACIFICA
Tors
ion
Stiff
ness
(kN
m/o
)
Torsion Stiffness
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#GDIS | #SteelMatters 40 ©2016-17 FCA US LLC
NVH – Vertical Bending
Improved Body Bending Rigidity • Continuous rail loadpaths • Minimized upperbody breathing • Strategic placement of modal nodes
32.2 37.6
28
32
36
40
Town & Country PACIFICA
Freq
uenc
y (H
z)
BIW 1st Bending Mode
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#GDIS | #SteelMatters 41 ©2016-17 FCA US LLC
Vertical Bending Response
Competitor A Town & Country
Improved Body Bending Rigidity • Reduced excitation of body structure to P/T, Chassis
vibration inputs • Improved ride and shake performance • Advanced topology-based stiffness optimization techniques
targeted strategic areas for modeshape improvement
PACIFICA
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#GDIS | #SteelMatters 42 ©2016-17 FCA US LLC
NVH/Dynamics – Lateral Bending
Multi-ring body structure concept • Continuous, multi-plane ring structure
• Bolt-in FEM-load beam braces
• Solid-mounted cradle for improved isolation, front end stiffness and vehicle dynamics
FEM-Load Beam Brace
40 44.8 47
36
40
44
48
Town & Country PACIFICAw/o Braces
PACIFICAFreq
uenc
y (H
z)
BIW Lateral Mode
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#GDIS | #SteelMatters 43 ©2016-17 FCA US LLC
NVH – Local Attachment Stiffness
Significant stiffness improvement at key noise and vibration input points
• Engine Mounts
• Trailing Arm Attachment
+250%
+85%
100 150 200 250 300 350 400 Frequency (Hz)
100 150 200 250 300 350 400 Frequency (Hz)
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#GDIS | #SteelMatters 44 ©2016-17 FCA US LLC
Press Reviews It’s certainly the best minivan I’ve driven, but it might be better than a number of popular crossovers too. James Derek Sapienza – Autos Cheat Sheet
The suite of safety features seamlessly picked up where my mirrors and windows left off, and the big V6 moved the 4,350-pound van well enough to not leave me wanting for anything when accelerating for lane changes and stop lights. James Derek Sapienza – Autos Cheat Sheet
Riding on an all-new platform with 22 percent more high-strength steel and close to 130 meters of structural adhesives—thus boasting a 68 percent increase in stiffness—the Pacifica proved as solid as it did quiet. No squeaks or rattles and minimal wind and road noise. – Ron Kino - Motortrend
At an estimated 4,300 pounds, the Pacifica is about 250 pounds lighter than the old Town & Country. Credit the weight loss to the bump in high-strength steel, not to mention the introduction of aluminum sliding doors and an aluminum-magnesium liftgate. Ron Kino - Motortrend
Slapping aggressive price tags on a minivan is one thing. Backing it up with best-in-class performance and functionality is another. With Pacifica, Chrysler has successfully managed to do both. And it has sculpted what is for all intents and purposes a box into a sleek, sexy benchmark of style. Ron Kino - Motortrend
No, minivans aren't cool, but the 2017 Chrysler Pacifica is close – Antuan Goodwin – Road Show by CNET It also looks like a spaceship mated with a Ninja Turtle when
viewed from straight on. This kind of funky, kind of cool look adds to the Pacifica's curb appeal, I think. Antuan Goodwin – Road Show by CNET
All-new 2017 Chrysler Pacifica Named to Wards 10 Best Interiors List for
2016
“You guys remember, ‘Get Shorty,’ right?...It’s cool driving a minivan.” President Barack Obama - NAIAS
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#GDIS | #SteelMatters 45 ©2016-17 FCA US LLC
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#GDIS | #SteelMatters 46 ©2016-17 FCA US LLC
For More Information
James Truskin Technical Fellow Body Adv. Architecture Fiat Chrysler Automobiles US LLC
Jeff Tibbenham System Responsible BIW Fiat Chrysler Automobiles US LLC
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Presentations will be available May 22 at www.autosteel.org