22 november2012 / rob ruifrok light weight steel solutions ... · electrical vehicle (and 3...
TRANSCRIPT
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Light Weight Steel Solutions in Automotive Design
22 november 2012 / Rob Ruifrok
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Inhoud
• Inleiding Tatasteel R&D
• Licht gewicht in de autoindustrie
• Super light Car project
• Future Steel Vehicle project
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3% 3%4%
6%
15%
24%
45%
Consumentenproducten
Dienstverlening
Chemie
Energie
IT
Engineering
Materialen
� Indiaas industrieel concern opgericht door JN Tata• Een historie van meer dan 140 jaar
� Totale omzet $ 70.8 miljard (boekjaar2009)
� Actief in 7 bedrijfssectoren
� Meer dan 350 000 medewerkers in 80 landen
Tata Sons
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Tata Steel Group – a diversified Global Steel Player
Tata Steel Group
• One of the world’s top ten steel companies in terms of crude steel production volume
• Crude steel capacity of approx. 28 Mn tonnes*
• A balanced global presence in over 50 markets and manufacturing operations in 26 countries
• 81,000 fte across 5 continents
• Investments in Minerals Assets improving Raw Material Security
• Group turnover (FY10): US$23bn
• Group EBITDA (FY10): US$2.1bn
Steel making operationsDistribution and Commercial Centres including downstream assets
Mining assets & projects
Tata Steel Europe
• Crude steel capacity:
─ 18 mtpa
─ 2nd largest steel producer in Europe
• 35,000 employees
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Locaties Tata Steel Group R&D
VK totaal 350 FTE IJmuiden 445 FTE India R&D + SS 450 FTE (*)
JamshedpurIndia R&DIJTC
TTC
STC
AEG
TTC: Teesside Technology CentreSTC: Swinden Technology Centre (Rotherham)AEG: Automotive Engineering Group (Coventry)IJTC: IJmuiden Technology Centre
(*) FTE: Full Time Equivalent
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� Steel Metallurgy
� Coated Products
Applications:
� Automotive
� Industrial & Construction
� Packaging
* Thermo-Mechanical Treatment Simulator IJmuidenTC
R&D-organisatie Europa:Products & Applications
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Licht gewicht in de autoindustrie
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Requirements on Automotive materials
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Drivers in automotive development
Fuel consumption, CO2 reduction: less weight
Environment
Incremental changesCosts
Acceleration, speed, cost of ownership: less weight
Performance
Larger cars, more gadgets, more weightComfort
Add more material: more weightSafety
• Increased use of High Strength Steels and other light weight materials
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Toekomstvisie VW
M.Goede, ICAFT, 13 en 14 november 2012, Chemnitz
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FutureSteelVehicleLeading Edge Innovations for Steel Body Structures
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Nippon Steel
voestalpineKobe
U. S. SteelHyundai-Steel
Ansteel NUCOR
ArcelorMittal POSCO
Baosteel Severstal
China Steel Sumitomo
Tata Steel ThyssenKrupp
JFE USIMINAS
Automotive Group of the World Steel Association
ULSABUltraLight Steel Auto Body
ULSABUltraLight Steel Auto Body
ULSASUltraLightSteel Auto Suspensions
ULSASUltraLightSteel Auto Suspensions
ULSAB-AVCAdvanced VehicleConcepts
ULSAB-AVCAdvanced VehicleConcepts
ULSACUltraLight Steel Auto Closures
ULSACUltraLight Steel Auto Closures
More than
US$60 Million
WorldAutoSteel Membership
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Facts and goals of the study
• Facts
• FSV is the successor of the recognized lightweight studies ULSAB 1998 and ULSAB-AVC 2001
• Electrical vehicles are currently more demanding regarding weight saving so they are more challenging to prove that steel is the best choice
• Goals
• Development of a smart lightweight steel BIW for an electrical vehicle (and 3 derivates) projected in 2020 at large volume (100.000 p.a.)
• Demonstration of latest steel grades and steel part manufacturing technologies
• Development of sustainable and cost-effective solutions
Timing: 2008 – 2011
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Source: International Council on Clean Transportation
USA
JapanEurope
Australia
China
100
60
80
120
160
140
180
200
220
260
240
280
Grams CO2 /Km (Equivalent)
2003 2006 2009 2012 2015 2018 2021 2024 2027 2030Source: International Council on Clean Transportation
USA
JapanEurope
Australia
China
100
60
80
120
160
140
180
200
220
260
240
280
Grams CO2 /Km (Equivalent)
2003 2006 2009 2012 2015 2018 2021 2024 2027 2030
Automotive CO2 Emissions Regulations
Why FutureSteelVehicle?
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Honda Clarity FCX
Mercedes E cell Plus
Early Introductions of Dedicated PlatformAdvanced Powertrain Vehicles
Why FutureSteelVehicle?
From www.bmw-i.nl
From www.renault.nl
BMW i3
Renault Twizy
Volkswagen
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Phase 1: Advanced Powertrain Options
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FSV Design Drivers
• Mass reduction
• Cost
• Total vehicle carbon footprint reduction
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Raising the Bar in Vehicle Mass Reduction
Baseline:
former, mild
steel design
ULSAB, ULSAB-AVC FutureSteelVehicle
(FSV)
-21 to 40%
-25%
-35%
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Mass Targets
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T1
T6
T5
T4
T3
T2Linear-StaticTopology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimisation
(LF3G)Sub-SystemTopographyOptimisation
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2
Report
FSV Development Process
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BEV
FCEV
PHEV
Occupant Package
Phase 1: Advanced Powertrain Options
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LF3G design optimization*
Topology optimization
Subsystem optimization
Submodel selection
• Front rail
• Shotgun
• Rocker
• B-pillar
• Rear rail
• Roof rail
• Tunnel reinf.
Design Optimization Process
Complete modeloptimization
*Low Fidelity Grade, gauge & geometry
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Material portfolioULSAB-AVC
Additional Steel grades FSV
Mild 140/270 DP 350/600 TRIP 600/980
BH 210/340 TRIP 350/600 TWIP 500/980
BH 260/370 SF 570/640 HSLA 700/780
BH 280/400 HSLA 550/650 DP 700/1000
IF 260/410 TRIP 400/700 CP 800/1000
IF 300/420 SF 600/780 MS 950/1200
DP 300/500 CP 500/800 CP 1000/1200
FB 330/450 DP 500/800 DP 1150/1270
HSLA 350/450 TRIP 450/800 MS 1150/1400
HSLA 420/500 CP 600/900 CP 1050/1470
FB 450/600 CP 750/900 HF 1050/1500
HSLA 490/600 MS 1250/1500
Nomenclature:Type of materialminimum yield strength/minimum tensile strength
Expected to be availableuntil 2020
� State of the art steel grades and developments for the near future were applied for the project
FSV Steel Portfolio
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Comparison of Subsystem Results
Weight (kg)
Cost(USD)
Aluminum
Hot stampedLWB Cold stamped
LWB
4,98 kg per part
22 USD
Cost / Weight comparison Selected solution
Lines of constant value= 9.39 USD/kg
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US NCAP EURO NCAP FMVSS 301 Rear ECE R32
IIHS Side FMVSS 214 PoleEURO NCAP Pole
FMVSS 216a, IIHS Roof RCAR/IIHS Low Speed
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Evaluation
FSV Crash Safety Analysis
EURO NCAP
A
Global crash requirements
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� Durability, Ride and handling analysis
� Static and Dynamic Stiffness
• Torsion Stiffness
• Bending Stiffness
• Global Modes
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� Noise, Vibration and Harshness
Additional Structural Analysis
Fish-hook test, double lane change maneuver (ISO 3888-1), 3g pothole test, 7g constant radius turn test, 0.8g forward braking test)
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Forming, Cost and LCA
� Manufacturing simulation:
• One step forming simulation
• Incremental analysis for complex parts
• Hot stamping simulation
� Manufacturing planning and cost study
� Life Cycle Assessment
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Material Classes
53%
3%
33%
33%
4%
43%
2%
10%
8%11%
0%
20%
40%
60%
80%
100%
HF
UHSS (CP, MS)
AHSS (DP, TRIP, TWIP)
HSS (HSLA, BH, IF)
Mild
FSV (2020)
Polo V2009
FSV2020
� Significant increasing share of AHSS, UHSS and hot forming steels
14%
64%
33%
46%
5%5%
11%
Audi A12010
21%
VW Polo (2009)
Audi A1 (2010)
188 kg
• Comparison with state of the art compact cars
Source: Eurocarbody 2009ATZ extra 06/2010
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Source: Argonne National Laboratory
LCA is needed to avoid Unintended Consequences
Life Cycle Assessment (LCA) of Greenhouse Gases
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Impact Well-to-Wheel on CO2 Emission
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2470 mm
701 mm
839 mm 661 mm
2524 mm 595 mm
3.6
3.71
Contact area (m²)
Body Structure Mass (kg)
Powertrain mass (kg)
FSV 190 (target) 329
VW Polo 231 233
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FSV vs. typical EU B-car (VW Polo 2010)