a winner: car body design development of the hyundai …/media/files/autosteel/great designs in...

w w w . a u t o s t e e l . o r g

A Winner: Car Body Design Development of the Hyundai Sonata

Carsten Höfer Hyundai Motor Europe Technical Center

• Background • History • Customer proposition • Styling • Practicality • Performance • Efficiency

• Development process • Platform strategy • Weight optimization • Stiffness • Material • Safety

• Overview of Ulsan Plant • Manufacturing strategy • Flexible production system • Productivity • Quality

Hyundai Sonata at GDIS Conference 2013

Product Concept BIW Concept /

Product Concept

• Background • History • Customer proposition • Styling • Practicality • Efficiency

• Development process • Weight optimization • Stiffness • Material • Safety

BiW Concept

i40 intro.m4v

Product Concept Hyundai Sonata at GDIS Conference 2013


7

2010 Sedan 2011 Sedan & Wagon

2004

1998




Product Concept

• Best in class roominess • Class leading practicality

• Sporty and emotional • Modern interior

• Target best in TCO • Competitive pricing

• 3 USPs: rear seat reclining, auto defog, heated steering wheel

• Best in class with 113g CO2/km


Product Concept BIW Concept

Product Concept

• Cargo capacity 19. 5 cu. ft. (553 liters) with the rear seats occupied • Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down


/

Product Concept

0.32

0.29 0.30

0.29

Predecessor i40 Competition

Cd

8,013

8,878 8,840


10,082 22%

132

155 148


CO2 (g/km)

214




BIW Concept Hyundai Sonata at GDIS Conference 2013


BIW Concept

SOP

SOP

-6 -4 -2

Full schedule predecessor 24M

Full schedule i40 18M

Model Fix

Design

Design Model Fix

Test

Test



BIW Concept

• Achieved a 7.6% reduction in BIW weight compared to predecessor.

438kg

Design concept Final drawings

456.3kg

Competition

438kg

EVI process

Design optimization -27.3kg


BIW Concept

• Rearranging the part assembly allowed for a reduction of the material thickness • From single part with uniform thickness to three parts with different, optimized thickness



BIW Concept

• Change of the form from linear interior to radial interior lead to a material thickness reduction • Divergence angle to improve airflow and NVH performance



Spare Member (0.8 ) Spare Member (1.0 )

BIW Concept

• Increased the torsional stiffness by 141% and the bending stiffness by 19%. • Achieved 11% more torsional and 23% more bending stiffness compared to competition

0.32

24

14.6 0.29

Predecessor i40

28.6 35.3




BIW Concept

• Continuous members from engine room to rear floor in longitudinal direction • Connections of floor, sides and roof form closed circular structures • Main joints optimized by extensions and closed profiles


BIW Concept

• The formation of a closed section connecting the underbody, cowl area and suspension strut improves the stiffness of the front-area • This also increases the local stiffness of the suspension strut dome resulting in improved driving performance

+87%




BIW Concept

• The vehicle rear end is reinforced by a double structure ring shape section • The ring shapes are interconnected in longitudinal direction by the rear side members, waistline profiles and roof rails

+67%



BIW Concept

• The roof stiffness is increased by local extensions • Optimized energy flow through maximized overlap • Increased local stiffness through constant section profile



BIW Concept

• Application of 71m of structural adhesives leads to body stiffness increase of 14%


Product Concept

Hyundai i40 at Euro Car Body Conference 2011 BIW Concept

6.1 3.1 3.6

28.5

35.6

23.2

MS (120 – 280 MPa)

HSS (180 – 640 MPa)

AHSS (220 – 720 MPa)

UHSS (620 – 1280 MPa)

PHS (980 -1260 MPa)

Fibre reinforced plastic




BIW Concept

EuroNCAP comments: • Driver knee airbag is standard equipment • Maximum score for side barrier impact • Bumper area scored maximum points for pedestrian protection • Speed limitation assistance is standard equipment for best selling variant



BIW Concept

20%

80%

20%

4%

12%

4%

14%

36%

30%

100%

89%

11%

24%

64%

12%



BIW Concept

1 2

3



BIW Concept

1.3% 13.2%

16.3%

12.3%

12.6%

21.1%

12.0%

11.2%


Product Concept Hyundai Sonata at GDIS Conference 2013 Hyundai Sonata at GDIS Conference 2013

Product Concept

• World Car Concept • Focused on local market customer demands • Supporting Hyundai’s philosophy of “Modern Premium” • Featuring Hyundai’s design language of “Fluidic Sculpture”

BiW Concept

• Streamlined development process of 18 months • CAE driven design for best performance and lowest cost • Highly efficient use of High Strength Steels • Excellent Light Weight Index to meet ecological demands • Safe for Occupants and Pedestrians

w w w . a u t o s t e e l . o r g

North American Light Vehicle Metallic Material Trends

Great Designs in Steel is Sponsored by:

Use your web-enabled device to download the presentations from today’s event

PRESENTATIONS WILL BE AVAILABLE MAY 3

a winner: car body design development of the hyundai …/media/files/autosteel/great designs in...

Documents