a winner car body design development of the hyundai sonata.pdf

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A Winner: Car Body Design Development of the Hyundai Sonata

Carsten Hfer 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 Hyundais philosophy of Modern Premium Featuring Hyundais 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

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North American Light Vehicle Metallic Material Trends

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a winner car body design development of the hyundai sonata.pdf

Documents

gdis conference

design concept final

biw weight

nvh performance hyundai

g co2km hyundai sonata

predecessor i40 competition

schedule i40

schedule predecessor