The Auto/Steel Partnership (A/SP) Lightweight Front End Structures study demonstrates the mass reduction enabled by the application ofAdvanced High-Strength Steels (AHSS) to a conventional high-strength steel front rail/bumper system of a 2004 production design 5-passenger mid-size sedan. The solution is constrained by the established package space and addresses the real world challenges faced in vehicle development and high volume manufacturing while meeting the frontal NCAP 35 mph rigid barrier impact; frontal IIHS 40 mph deformable barrier offset impact, static stiffness and dynamic stiffness design targets. The Laser Welded Blank (LWB) Stamped solution demonstrating an 8.77 kg (22.4 percent) mass savings was fabricated and validated in full vehicle crash testing. Recent work and the focus of this paper discusses a Tailor Welded Tube (TWT) hydroform solution achieving a 10.4 kg (26.5%) and 12.4 kg (31.8%) mass savings while meeting all performance objectives. This paper presents a cost evaluation demonstrating both the LWB Stamped solution and TWT Hydroform solution can be manufactured in high volume at cost parity with the existing baseline production design.
A/SP lightweight front end structure - hydroform solution and cost analysis
2006
7 Seiten, 21 Bilder
Aufsatz (Konferenz)
Englisch
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