2016 Chevrolet Malibu 2017 Buick LaCrosse/media/Files/Autosteel/Great... · 2016-05-16 · 2016...
Transcript of 2016 Chevrolet Malibu 2017 Buick LaCrosse/media/Files/Autosteel/Great... · 2016-05-16 · 2016...
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Lightweighting and steel technologies in the all-new
2016 Chevrolet Malibu 2017 Buick LaCrosse
Terry A. Swartzell Underbody System Architect
General Motors Company May 11, 2016
v2
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AGENDA
The new sedans
Mass reduction hierarchy
Part sharing
Steel technologies
Crash examples
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THE NEW SEDANS
2016 Chevrolet Malibu
• 9th generation
• 111” wheelbase
• Sold in 18 countries around the world
• 3 assembly sites (Fairfax, China, Korea)
2017 Buick LaCrosse
• 3rd generation
• 114” wheelbase
• Sold in US, Canada and China
• 2 assembly sites (Detroit Hamtramck & China)
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EFFICIENTLY POWERFUL
All-New 1.5L Turbo
• 6-speed auto transmission
• 160 hp / 184 ft-lb of torque
2.0L Turbo
• 8-speed auto trans
• 250 hp / 258 ft-lb of torque
1.8L Hybrid
• 60 cell / 1.5 kWh Li-Ion battery
• Leverages Volt technology
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2017 BUICK LACROSSE
• 3.6L V6
• Quiet-Tuning
• Stronger, longer, stiffer & lighter
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STRONGER, LONGER, STIFFER & LIGHTER
2016 Malibu BIW: ~331 kg*
• 2.3” longer OAL vs predecessor
• 3.6” longer W/B vs predecessor
2017 Lacrosse BIW: ~343 kg*
• 0.5” longer OAL vs predecessor
• 2.7” longer W/B vs predecessor
Body structure ~ 100 lbs lighter than previous generation
(Vehicle ~ 300 lbs lighter)
* BIW structure, paint, sealer, adhesive, bolt-on braces, etc
2016 Malibu BIW: ~331 kg* 2017 Lacrosse BIW: ~343 kg*
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GM’S BODY MASS REDUCTION HIERARCHY
• Efficient integration of systems
• Aggressive CAE iteration & optimization
• The right performance targets
• Efficient design fundamentals
• The right steel grades
Lower
Higher
Influence on body
mass
kg
• Efficient integration of systems
• Aggressive CAE iteration & optimization
• The right performance targets
• Efficient design fundamentals
• The right steel grades
• Control of architectural bandwidth • Control of architectural bandwidth
• Execution excellence (short flanges, scallops, lightening holes, etc)
• Execution excellence (short flanges, scallops, lightening holes, etc)
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GM’S BODY MASS REDUCTION HIERARCHY
• Control of architectural bandwidth
• Efficient integration of systems
• The right performance targets
• Aggressive CAE iteration & optimization
• Efficient design fundamentals
• The right steel grades
• Execution excellence (short flanges, scallops, lightening holes, etc)
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ARCHITECTURE BANDWIDTH
2016 FWD
Malibu
LaCrosse AWD
long W/B
GM OLD APPROACH: “ONE UNDERBODY FITS ALL”
Scar Mass
Possible future Derivatives and variants (Bubble size indicates global volume)
GVM
(kg)
Illustrative only not to scale
Possible future derivatives & variants
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ARCHITECTURE BANDWIDTH
2016 FWD
Malibu
LaCrosse AWD
long W/B
GM NEW APPROACH: “MANAGED BANDWIDTH”
Possible future Derivatives and variants (Bubble size indicates global volume)
GVM
(kg)
Illustrative only not to scale
Possible future derivatives & variants
Higher mass optimization point
High volume low mass
optimization point
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ARCHITECTURE BANDWIDTH
• 4 cylinder only • FWD only • Base FWD tunnel • Base W/B • 4-link rear suspension • Base strut front suspension • Lower GVM’s
• V6 engine • FWD & AWD • Larger AWD tunnel • Longer W/B & ROH • 5-link rear suspension • HiPer strut front suspension • Higher GVM’s
2016 Malibu optimized for: 2017 Lacrosse optimized for:
Higher mass optimization point Low mass optimization point
• Minimum scar mass
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BODY STRUCTURE SHARING STRATEGY COMMON SOLUTIONS – UNIQUE PARTS
Low mass optimization point
2016 Chevrolet Malibu
Higher mass optimization point
2017 Buick LaCrosse (NA)
Malibu base parts Common w/Malibu
Trim change only
Unique to LaCrosse
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GM’S BODY MASS REDUCTION HIERARCHY
• Control of architectural bandwidth
• Efficient integration of systems
• The right performance targets
• Aggressive CAE iteration & optimization
• Efficient design fundamentals
• The right steel grades
• Execution excellence (short flanges, scallops, lightening holes, etc)
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AGGRESSIVE VIRTUAL DEVELOPMENT
Optimization iterations
Visualization & interpretation iterations
Concept design iterations
Optimization iterations
Visualization & interpretation iterations
Concept design iterations
• 6 virtual gates per model
• 2832 standard loadcases
• 10 million CPU hours
• 6 virtual gates per model
• 2832 standard loadcases
• 10 million CPU hours
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FULLY OPTIMIZED FINAL ITERATION
Planar & parallel faces
Extended seatback beam
Multi-piece gusset
Integrated right-sized sections
1
2
3
4
Extended seatback beam 1
Planar & parallel faces 2
Multi-piece gusset 3
Upper seatback
section
Max
Ixx
Integrated right-sized sections 4
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RESULTS: STIFFER PERFORMANCE
Global Static Torsion (kN-m/deg)
New Malibu Predecessor Malibu
Base roof: 23.0
21.6
28.4
23.6
+23%
+9% Sunroof:
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HIGH EFFICIENCY FRONT TOPOLOGY CONCEPTS
Upper rail flows
into cradle standoff
Hoop structure between struts 3
5
Stiff powertrain mount loadpaths 2
Drag section tubes & stampings 4 Drag section tubes & stampings 4
Strut tower - A pillar loadpath 1
Upper rail flows
into cradle standoff 5
Strut tower - A pillar loadpath 1
Hoop structure between struts 3
2 Stiff powertrain mount loadpaths
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Unit load
PERFORMANCE RESULTS: STIFF CONTINUOUS HIGH QUALITY DEFORMED MODES
Upper rail flow into
cradle standoff 5
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N&V IS KEY DRIVER OF TOPOLOGY
Structure Goals: Maximize mount isolation.
Minimize vibration sensitivity.
Source Powertrain and road
Path Structure
Receiver Cabin noise and vibration
Example: engine pulse response optimization
Example: Cradle mount dynamic stiffness development.
2
2 Minimize vibration sensitivity.
1
1
Maximize mount isolation.
Structure Goals:
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GM’S BODY MASS REDUCTION HIERARCHY
• Control of architectural bandwidth
• Efficient integration of systems
• The right performance targets
• Aggressive CAE iteration & optimization
• Efficient design fundamentals
• The right steel grades
• Execution excellence (short flanges, scallops, lightening holes, etc)
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EFFICIENT DESIGN FUNDAMENTALS
• Thin skins • Stable sections • Bulkheads • Local reinforcement • Bolt-in struts
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EFFICIENT FUNDAMENTALS EXAMPLE BOLT-IN N&V STIFFENER
Achieves key target for dynamic stiffness
Low mass - very effective
Allows lean “down-rigger” structure
Unit load
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EFFICIENT DESIGN FUNDAMENTALS
54 meters of structure adhesive
Supplements spot welds
Improved durability at thin gauges
Enhances stiffness
Arc welding/brazing
Used in high value areas
Allows single sided joining
Allows smaller, stiffer sub-assemblies
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GM’S BODY MASS RED’ N HIERARCHY
• Control of architectural bandwidth
• Efficient integration of systems
• The right performance targets
• Aggressive CAE iteration & optimization
• Efficient design fundamentals
• The right steel grades
• Execution excellence (short flanges, scallops, lightening holes, etc)
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THE RIGHT STEEL GRADES
Mild PHS &
martensite
Dual phase & multi-phase
HSLA Bake hardenable
7%
34% 24%
9%
27%
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•Thicker at max bending moment
•Long thickness transitions
Variable thickness blank
Side view of part
Thin Thin Thick
HIGH THICKNESS ONLY WHERE REQUIRED
transitions
Thickness profile*
* Thickness profile optimized for Malibu. Reinforcement added for higher GVM LaCrosse.
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Co-formed patch blank utilization
Co-formed dash & constrained layer doubler
Co-formed PHS B-pillar and reinforcement
• PHS patch on PHS pillar • Avoids dimensional issues • Maximizes weld flats
• Steel-viscoelastic-steel sandwich in key N&V area
• Net vehicle mass savings (lower acoustic mass)
HIGH THICKNESS ONLY WHERE REQUIRED
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HIGH THICKNESS ONLY WHERE REQUIRED
Laser welded rail blanks
`````
```
```
Front rail inner
Front rail reinf
Front rail outer
Varying thickness &
grade
Varying thickness
Varying thickness &
grade
Varying thickness & grade
Rear rail lower
Front rail rear extension
Varying thickness & grade
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LASER WELDED RAIL BLANK
Example: China NCAP rigid moving barrier
TUNING EXAMPLE
Gauge and grade in each zone optimized for performance
Zone
C A Zone
B Zone
Crush Fold Backup
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CRASH EXAMPLE
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SMALL OVERLAP PERFORMANCE
Vehicle deflection Strong back-up structure
• Bolt-on body parts • Cradle deflector
• High part strength • High weld strength
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Vehicle Deflection Strong backup structure
SMALL OVERLAP ANALYTICAL DEFORMATION
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THANK YOU FOR YOUR ATTENTION!