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FutureSteelVehicle Design Methodology: Detail Design Concept using 3G Optimization
Technical Paper
2012-01-1345
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
As worldwide demand for affordable, safe and low greenhouse gas
emission vehicles surged, WorldAutoSteel launched the
FutureSteelVehicle program (FSV) aimed at helping automakers
optimize body structures through advanced steel design concepts
suitable for both conventional and electrified powertrains. The
objective was to develop detailed design concepts and fully
optimize a radically different body structure vehicle in production
in 2015-2020 timeframe utilizing the latest grades of advanced and
ultra-high strength steels. FSV achieved 35 percent mass reduction
[approaching aluminum body structure mass with similar
performance], at no additional cost over a conventional steel body
while achieving simulated crash test performance enabling a 5-star
safety rating. This was accomplished with a portfolio of 34
standard and advanced steel grades and 17 steel manufacturing
technologies together with a state-of-the-future design
methodology. The body structure contained 97 percent high-strength
and advanced high-strength steel (HSS & AHSS) with 44 percent
of these in the GigaPascal strength range.
FutureSteelVehicle Design Methodology is a product design
optimization methodology that has been developed by Engineering
Technology Associates, Inc., (ETA) and WorldAutoSteel into
ETA's Accelerated Concept to Product (ACP) Process™ utilizing
the latest steel grades available by 2015 and the latest in
manufacturing processes to achieve a 35% BIW mass reduction while
achieving all vehicle performance targets at an early design
concept level.
The FutureSteelVehicle Design Methodology creates many design
solutions and options. This paper provides an insight to the
de-coupling process of the vehicle to subsystem (components) models
and the optimization process that allows designing components into
diverse, non-intuitive shapes that could follow nature and organic
shapes. The paper examines 10 potential design solutions out of 537
designs for the front longitudinal rail sub-system and reports
their results. The study shows the many design solutions that are
available utilizing different gauges, grades, geometries and
various manufacturing techniques while still meeting all of the
design requirements.
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Authors
Citation
Powers, J., Laxman, S., Farahani, A., and Sharifi, H., "FutureSteelVehicle Design Methodology: Detail Design Concept using 3G Optimization," SAE Technical Paper 2012-01-1345, 2012, https://doi.org/10.4271/2012-01-1345.Also In
References
- EDAG AG 2010 Phase 2 FutureSteelVehicle Steel Technology Assessment and Design Optimization Engineering Report www.worldautosteel.org/Projects/Future-Steel-Vehicle/FSVInterimReport.aspx
- Engineering Technology Associates, Inc. (ETA) 2009 Methodology Used in Future Steel Vehicle Wins SAE Vehicle Innovation Competition www.theautochannel.com/news/2009/12/18/459143.html
- Farahani, A. Averill, R.C. Sidhu, R. “Design Optimization of Hydroformed Crashworthy Automotive Body Structures,” CAD-FEM Users' Meeting Berlin, Potsdam, Germany November 12 14 2003
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- Farahani, A. Shaw, J. “Future Generation Passenger Compartment” Great Designs in Steel (GDIS) May 2007
- Auto Steel Partnership “Future Generation Passenger Compartment” (FGPC) Validation November 2009
- Madakacherry, J.M. Eby, D. Isaac, M. B. Farahani, A. Bruggeman, C. Averill, R. C. “A Process of Decoupling and Developing Optimized Body Structure for Safety Performance,” “10 th European LS-DYNA Conference.” March 18 2004
- Farahani, A Shaw, J. “Highly Optimized Longitudinal Rail Achieving 45% Mass Reduction” Great Designs in Steel (GDIS) May 2009