VE Commodore Body Structure - Australasian Road Rescue Organisation
Transcript of VE Commodore Body Structure - Australasian Road Rescue Organisation
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VE CommodoreBody Structure
Mark HicksonManaging Engineer & System Architect – Body Structure
GM Holden
iRescue Symposium24 July 2010
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Introduction
• VE and WM sedans launched 2006
• Ute launched 2007
• Wagon launched 2008
• Most comprehensive body in white program ever
• Stiff body structure ranks among best large cars
• Crash performance, N&V improvements, occupant safety – biggest wins
• High strength steels – significant increase in usage
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Introduction
• Entire architecture program done virtually
• Crash and durability modellingused extensively
• Accuracy, cost efficiency and speed to market
• Concept and feasibility studies began in 1999
• Benchmarks includedMercedes, Audi and BMW
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Crash performance
• Met offset frontal, full frontal, rear and side impact requirements
• 5 star ANCAP rating
• Met front crash requirementsdespite reduced crush space
• Use of high-strength steels
• Careful design of front railsection and joints
• Clearly defined load paths
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Crash performance
• For frontal impact, three load paths created through upper rails, longitudinal rails andengine cradle
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Crash performance
• For side impact, load paths include B pillar, IP cross-beam, three floor cross-members, rocker, door intrusion beam, structural roof bow design
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Crash performance
• For rear impact, strategy involved rear longitudinal rail, rocker and C pillar brace design
• Fuel tank relocated to be forward of rear wheels
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Material utilisation and body stiffness
• Weight a key issue
• Achieved a very high level of body stiffness
• Torsion and bending modes increased enormously – excellent structural feel, sense of safety and solidity
• One-piece body side outer
• biggest Holden has ever produced
• Delivers quality improvements
• better fit and finish
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Automotive steels used in VE
1. Low strength
• mild steel & interstitial-free (IF) steel, used for skin panels, small brackets
2. Medium strength
• bake hardening, used for door skins
3. Conventional high strength
• HSLA / High Strength Low Alloy, used for structural members
4. Advanced high strength
• dual phase (DP), recovery annealed, used for rockers, cross-members
5. Ultra high strength
• hot stamped / press-hardened, used for Centre Pillar, door beams
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Automotive steels used in VE
Low Strength
Medium Strength
High Strength
Advanced High Strength
Ultra High Strength
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Automotive steels – mechanical properties
Grade Yield Strength
(MPa)
Tensile Strength
(MPa)
Elongation(%)
Low Strength 140-180 270-330 40
Medium Strength 180-300 300 min 32
High Strength 340-400 400 min 22
Advanced High Strength 550-700 980 min 10
Ultra High Strength 950-1100 1200 min 8
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Steel Usage – VT to VZ
MediumStrength 12%
Low Strength 88%
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Steel Usage – VE
MediumStrength 32%
Low Strength 19%
High Strength Steel 36%
Ultra High Strength Steel 3%
Advanced HighStrength Steel 10%
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Steel Usage
Low Strength
Medium Strength
High Strength
Advanced High Strength
Ultra High Strength
Aluminium
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High Strength Steel Usage
YS=340-400 MPa HIGH STRENGTH
YS=550-700 MPa ADVANCED HIGH STRENGTH
YS=950-1100 MPa ULTRA HIGH STRENGTH
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Steel Usage – Press Hardened / Hot Stamped
• Ultra high strength steel
• Centre Pillar Reinforcement
• YS = 950MPa, TS = 1200MPa
• Blank is heated above 900˚C, stamped, quenched
• Enables complex geometry, little springback
• Process video
Centre Pillar Reinforcement
To
tal E
longation (
%)
Tensile Strength (MPa)
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Steel Usage – Dual Phase
• Advanced high strength steel
• Rocker Inner, #4 Bar, Rail Extn, U/B Brace
• YS = 650MPa, TS = 980MPa
• Folding, bending, simple stampings
Rocker Inner#4 Bar
YS=550-700 MPa DUAL PHASES
tress (
MP
a)
Strain
Rail Extn
U/Body Brace
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Steel Usage – Recovery Annealed
• Advanced high strength steel
• Rocker Outer
• YS = 700MPa, TS = 900MPa
• Roll-forming
Rocker Outer
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Steel Usage – HSLA
• Many underbody panels
• Yield strength = 340-400MPa
• Tensile strength > 400MPa
• Stamping process
YS=340-400 MPa HIGH STRENGTHS
tress (
MP
a)
Strain
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Steel Usage – HSLA
• Many upper structure panels
• Yield strength = 340-400MPa
• Tensile strength > 400MPa
• Stamping process
YS=340-400 MPa HIGH STRENGTH
Str
ess (
MP
a)
Strain
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Steel Technology – Tailor Welded Blanks (TWB)
• Efficient way of combining different thickness or material grade into a single component
• Two blanks (flat sheets) are laser welded together
• Stamped as a single part in a single die
• Mass saving, get thickness or strength in the right area
• Used in front rails, #2 cross-bar, door inner
BP 115813-V1 21
Front portion (grey) is lighter gauge (1.8mm)
Rear portion (blue) is heavier gauge (2.3mm)
Tailor weld line
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Composite wheel tub
• Lightweight spare wheel tub a GM first
• Composite – not steel
• Glued into steel body
• Delivered a weight saving of about 6kg
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The Future
MediumStrength
Low Strength
High Strength Steel
Ultra High Strength Steel
Advanced HighStrength Steel
MediumStrength
Low Strength
High Strength Steel
Ultra High Strength Steel
Advanced HighStrength Steel
Current 2013?
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Conclusion
• Body structure – among best and stiffest in the world
• First use of high strength steels for Holden
• Next generation will use even more advanced steels
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Questions?