lightweight saving solutions applied on - lbcg.com · lightweight saving solutions applied on new...

LIGHTWEIGHT SAVING SOLUTIONS

APPLIED ON

NEW PEUGEOT 3008

Sébastien CHOPARD

6th Annual Global Automotive Lightweight Materials Europe

AGENDA

GENERAL PRESENTATION

MATERIAL MIX

FOCUS ON B-PILLAR

FOCUS ON LOAD FLOOR

AGENDA

GENERAL PRESENTATION

MATERIAL MIX

FOCUS ON B-PILLAR

FOCUS ON LOAD FLOOR

GENERAL PRESENTATION

GENERAL PRESENTATION

I-Cockpit concept Opening roof

GENERAL PRESENTATION

+60 +62 +13

-15

114

+60

GENERAL PRESENTATION

GENERAL PRESENTATION

Mother car for:

5 Europe vehicles in 3 factories

4 China vehicles in 2 factories

4 brands

GENERAL PRESENTATION

Styling freedom on bodyside and rear area with same A pillar - B pillar and rocker reinforcer

GENERAL PRESENTATION

Roof rail improvement:

Laser brazed roof for perceive quality

Compact cross section

• Contribute to vehicle height reduction

• Maximize opening roof width

• More efficient shape for NVH

GENERAL PRESENTATION

High dynamic stiffness for NVH

First body mode :

• Continuous rear ring + Structural insert

• Rool up support and lower gusset

• Shear panel in rocker section

Upgrade prestations: Torsion dynamic stiffness

Stiff and light body to serve Peugeot driving dynamics

5 stars EuroNCAP 2016

GENERAL PRESENTATION

Lightweight index 𝑴

𝑲𝒕 ∗𝑨

AGENDA

GENERAL PRESENTATION

MATERIAL MIX

FOCUS ON B-PILLAR

FOCUS ON LOAD FLOOR

MATERIAL MIX

27,28%

31,01%

21,62%

0,20% 9,44%

1,50% 0,68%

0,68% 1,52%

0,79%

3,80%

1,47%

LSS

HSS

AHSS

UHSS

PHS

Sheet 6xxx

Sheet 5xxx

Extrusion 7xxx

Extrusion 6xxx

Duroplastic

Thermoplastic

Autre

Material mix of body and hang-on parts

Aluminium hood and fender

Full thermoplastic tailgate

MATERIAL MIX

Steel body with extended usage of PHS and AHSS

Duroplastic load floor as all EMP2 vehicles

25,88%

33,26%

28,24%

0,26% 11,12%

1,06% 0,19%

LSS

HSS

AHSS

UHSS

PHS

Duroplastic

Autre

MATERIAL MIX

Increased usage of PHS in the safety cage area:

DP steels both in stamping and roolforming:

3008

2 + 2 Parts

New 3008

10 + 10 parts

980 Mpa Stamped 1180 Mpa Roolformed 780 Mpa Stamped

MATERIAL MIX

Multi-thickness technology:

TRB TWB

MATERIAL MIX

Mass walk from 3008 to New 3008 BIW

250

260

270

280

290

300

310

320

330

340

350

-12%

AGENDA

GENERAL PRESENTATION

MATERIAL MIX

FOCUS ON B-PILLAR

FOCUS ON LOAD FLOOR

FOCUS ON B-PILLAR

308 3008

History construction B-Pillar : cutting of parts

Old 3008

FOCUS ON B-PILLAR

Old 3008 308 3008

History construction B-Pillar : material use

FOCUS ON B-PILLAR

AEMDB side crash scenario:

One piece TRB B-pillar with bending trigger in lower area

Strong roll-formed roof bow in DP 1180 grade

Sill bulkhead for seat cross member loading

PHS Diagonal door reinforcer

FOCUS ON B-PILLAR

Predictive calculation:

NOK

SAFE

RISK

FOCUS ON B-PILLAR

Correlation calcul – physical test:

FINAL SOLUTION ORIGINAL SOLUTION

AGENDA

GENERAL PRESENTATION

MATERIAL MIX

FOCUS ON B-PILLAR

FOCUS ON LOAD FLOOR

FOCUS ON LOAD FLOOR

SMC LOAD FLOOR

FINAL ASSEMBLY BODY SHOP ?

BODY SHOP

Assembly sequence:

Concept:

FOCUS ON LOAD FLOOR

FOCUS ON LOAD FLOOR

Welding point

Sealing

Glue and screw

Welding point

Sealing

BODYSHOP FINAL ASSEMBLY

Assembly:

Modularity:

FOCUS ON LOAD FLOOR

SMC STEEL

Modularity:

FOCUS ON LOAD FLOOR

FOCUS ON LOAD FLOOR

Synthesis:

≈ -35% weight saving

No process impact to manage steel and SMC versions

Less fixations

No crack in rear reparability crash

CONCLUSION

Vielen Dank

Thank you

ありがとう

Grazie

Merci