FutureSteelVehicle Design Methodology: Detail Design Concept using 3G Optimization Severstal North America Incorporated

Format:

Conference/Event

Author/Creator:

Powers, Powers, author.

Contributor:

Farahani, Akbar

Laxman, Srinivasan

Sharifi, Hamed

Conference Name:

SAE 2012 World Congress & Exhibition (2012-04-24 : Detroit, Michigan, United States)

Language:

English

Physical Description:

1 online resource

Place of Publication:

Warrendale, PA SAE International 2012

Summary:

As worldwide demand for affordable, safe and low greenhouse gasemission vehicles surged, WorldAutoSteel launched theFutureSteelVehicle program (FSV) aimed at helping automakersoptimize body structures through advanced steel design conceptssuitable for both conventional and electrified powertrains. Theobjective was to develop detailed design concepts and fullyoptimize a radically different body structure vehicle in productionin 2015-2020 timeframe utilizing the latest grades of advanced andultra-high strength steels. FSV achieved 35 percent mass reduction[approaching aluminum body structure mass with similarperformance], at no additional cost over a conventional steel bodywhile achieving simulated crash test performance enabling a 5-starsafety rating. This was accomplished with a portfolio of 34standard and advanced steel grades and 17 steel manufacturingtechnologies together with a state-of-the-future designmethodology. The body structure contained 97 percent high-strengthand advanced high-strength steel (HSS and AHSS) with 44 percentof these in the GigaPascal strength range.FutureSteelVehicle Design Methodology is a product designoptimization methodology that has been developed by EngineeringTechnology Associates, Incorporated, (ETA) and WorldAutoSteel intoETA's Accelerated Concept to Product (ACP) Process utilizingthe latest steel grades available by 2015 and the latest inmanufacturing processes to achieve a 35% BIW mass reduction whileachieving all vehicle performance targets at an early designconcept level.The FutureSteelVehicle Design Methodology creates many designsolutions and options. This paper provides an insight to thede-coupling process of the vehicle to subsystem (components) modelsand the optimization process that allows designing components intodiverse, non-intuitive shapes that could follow nature and organicshapes. The paper examines 10 potential design solutions out of 537designs for the front longitudinal rail sub-system and reportstheir results. The study shows the many design solutions that areavailable utilizing different gauges, grades, geometries andvarious manufacturing techniques while still meeting all of thedesign requirements

Notes:

Vendor supplied data

Publisher Number:

2012-01-1345

Access Restriction:

Restricted for use by site license