Advanced High -Strength Steel Technologies in the 2017 .../media/Files/Autosteel/Great Designs in...
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GDIS2017 ©2016-17 FCA US LLC
Advanced High-Strength Steel Technologies in the 2017 Chrysler Pacifica Jeff Tibbenham & James Truskin Fiat Chrysler Automobiles US LLC
#GDIS | #SteelMatters 2 ©2016-17 FCA US LLC
The First 5 Generations…
H E R I TA G E
The 1st - 1984 1991-1995 1996-2000 2001-2007 2008-2016
6M CUR R E NT O WN E R S
13 .5M+ UN I TS S O LD
14 CO N S E CUT I VE YE A R S
H I GHE S T LO YA LTY
3 A WA R DS
JD PO WE R I Q S
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Chrysler Pacifica
©2016-17 FCA US LLC
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Exterior Styling
©2016-17 FCA US LLC
#GDIS | #SteelMatters 5 ©2016-17 FCA US LLC
2017 PACIFICA Final Design
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Roof Options: 2 Cd: 0.3 Passengers: 8 Luxuriously crafted interior
Design Features
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Industry Leading
• 10” Seatback Touch Screens In 2nd Row
• Blu-Ray DVD • Wireless & HDMI
Device Connectivity • 7” TFT Instrument
Cluster
Technology & Entertainment
Modern & Stylish
• Tri-pane Vista View Sunroof
• 20” Wheels • LED Accent Lighting • Rotary Style E-Shift
Design
Comprehensive Feature Suite
• ParkView® Rear Backup Camera
• Surround View Camera • Forward Collision
Warning • Adaptive Cruise Control • LaneSense® Lane
Departure Warning • ParkSense®
Parallel/Perpendicular Park Assist With Stop
• KeySense™ Programmable Key Fob
Safety & Security
Efficient
• Hybrid Technology • Hands Free Sliding
Doors & Liftgate • Easy Tilt 2nd row Seats
w/Child Seat Preserve • Stow ‘n Vac™
Integrated Vacuum • Capless Fuel Fill • Push-Button Sliding
Doors • Keyless Enter ‘n Go™
Passive Entry / Push Button Start
Fuel Economy & Convenience
Multi-functional
• 8 Passenger Seating with Stow n’ Go®
• Stow n’ Go Assist® • Heated & Ventilated
Seats • Heated Steering Wheel • Power 3rd Row
Versatility & Comfort
Pacifica - “Why Buy” Pillars
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All New Hybrid Technology Most versatile and functional of
any Hybrid in the market
Innovative Package Battery in center of vehicle
• No compromise to cargo objectives • Neutral handling effects
Class-Leading Performance
PHEV Capability
2h r s CHARGE TIME
33mi le BATTERY RANGE
84 CITY EMPG
16kWh BATTERY
©2016-17 FCA US LLC #GDIS | #SteelMatters 9
©2016-17 FCA US LLC
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Challenges: Pacifica BIW Design
Quietist/Best Handling Minivan • Structural Rigidity & Isolation • Local Stiffness
• IIHS TSP+ (incl. GOOD SORB rating) • 5* NCAP • FMVSS Regulations
• 8 Passenger Seating • 2nd Row Width • 4’x8’ Plywood
• >10% Mass Reduction • Increased functional objectives
• Current model & Pacifica
manufactured on same line
• Minimize Downtime
• Protect Interior Space • Common Body Structure
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Engineering Development Process Voice of the Customer
Vehicle-Level Functional Objectives
Body System Functional Objectives
• Joints • Load Paths
• Sections • Materials
Design Execution Rapid Concept Development (RCD)
FCA toolset and strategic approach to BIW structure development
Faster concept → CAE assessment loop
Increased number of assessed concepts
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Rapid Concept Development (RCD) Process CAE ANALYSIS
Concept 2…
Concept 1
New Section Proposals
Benchmarking & Topology Optimization
OPTIMIZATION • Thousands of optimization runs • Structural knowledge building • Early mass reduction initiative
NEW RCD Baseline Model
JOINT STIFFNESS ASSESSMENT
Surrogate Geometry New Package
New Theme Detailed Design Material Selection
DESIGN DEVELOPMENT
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Load Path Concept Generation
Topology Optimization Production Design
Load Path Optimization • Critical activity for efficient use of material • Optimized structure around key packaging hard
points
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Pacifica BIW Design Optimization Tools
Panel Bead Optimization (Local Stiffness,
Mobilities)
Global Topology Optimization (Loadpaths)
Sub-System & Component Topology Optimization
(Efficiency)
Weld/Adhesive Optimization
Multi-Disciplinary Optimization – MDO
(Weight, Attribute Balancing)
Joint & Section Optimization
(Continuity)
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Weight Reduction Breakdown
“Pacifica Minivan lost 250 pounds [113kg].” - Detroit Free Press – Sunday, March 20, 2016
“At 4,315 pounds [1876kg], the new Pacifica is 250 pounds [113kg] lighter than the outgoing Chrysler Town & Country and is the lightest minivan on the road…” - Detroit Free Press – Sunday, March 20, 2016
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Weight Reduction Breakdown
-13% (76kg) TOTAL BODY SYSTEM WEGHT REDUCTION
- 2 2 % CLOSURES
- 1 2 % BIW
-11% FEM + BUMPERS
512 kg 452 kg
64 kg 50 kg
28 kg 25 kg
0100200300400500600
Syst
em W
eigh
t (kg
)
FEM & BumpersClosuresBIW
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BIW Materials: Mild Steel Applications
Mild Steel <210 MPa YS (115kg)
25.4%
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BIW Materials: HSS Applications
HS Steel >210 MPa YS (102kg) 22.6%
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BIW Materials: AHSS Applications
AHS Steel DP590 TRIP690 (135kg)29.9%
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BIW Materials: UHSS Applications
AHS Steel+ DP780 (37kg) 8.2%
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Hydroformed Upper Load Beam
• (2) DP780 Hydroformed tubes • Optimized strength, stiffness and load path
requirements around tight packaging
1.8 kg Saved per Vehicle
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BIW Materials: Press Hardened Steel (PHS)
Press Hardened Steel PHS1300, PQS550
(50kg) 11.1%
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Front Door Ring Strategy
• 5-piece, multi material welded blank • Eliminated insert and assembly operations • Weight = 13.7kg per side
10kg saved per vehicle
1.6mm PHS1300
1.3mm PHS1300
2.0mm PHS1300
1.6mm PQS550
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Component Testing and Validation
B-Pillar Component Simulation Model
B-Pillar Component Validation Test
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BIW Materials: Plastic Structural Inserts and Baffles
Plastic Structural Inserts & Baffles (2kg) 0.4%
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BIW Materials: Other – Metal–Plastic–Metal Laminates (NVH)
Other NVH Steel (11kg) 2.4%
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BIW Materials Strategy
Mild Steel <210 MPa YS
(115kg) 25.4%
HS Steel >210 MPa YS
(102kg) 22.6%
AHS Steel DP590 TRIP690 (135kg) 29.9%
AHS Steel+ DP780
(37kg) 8.2%
Hot Stamp PHS1300, PQS550
(50kg) 11.1%
Plastic Structural Inserts
(2kg) 0.4%
Other, NVH Steel
(11kg) 2.4%
7 2 % H S S 2017 PACIF ICA
1 2 STEEL GRADES
5 0 % H S S 2016 TOWN &
COUNTRY
9 5 0 M P a MAX Y IELD STRENGTH
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Impact Development
NHTSA RATING
TARGET
> 8 5 0 0 CAE SIMULATIONS
T S P + I IHS RATING
TARGET
REGULATORY 3rd PARTY (IIHS)
> 8 0 FULL VEHICLE IMPACT TESTS
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Frontal Impact Load Paths
Dual Impact Load Path Strategy • AHSS Front Rails (70%) • AHSS Front Cradle (30%)
• Engineered detach of front cradle rear mount for increased crush space
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SORB Impact Load Paths
Offensive and Defensive Structure • Body and Chassis systems work
together early in the event • AHSS Safety cage reduces passenger
compartment intrusions
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SORB Impact Load Paths Offensive Enablers • Early engagement of body rail and chassis structure initiate
lateral movement away from barrier • Integrated bumper and UHSS Load beam system
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SORB Impact Load Paths Defensive Enablers • AHSS/UHSS-Reinforced Safety Cage
• TWB Press Hardened door ring • Strategic flange conditions for welds in shear and
compression loading
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Rear Impacts Load Paths
AHSS/UHSS Rear Rail Assembly • Optimized rear rail topology and suspension
design for improved load path continuity and suspension clearance
• Optimized lateral bending mode of DP590 Rear Rail for efficient energy absorption
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FMVSS 216a Load Paths
UHSS Safety Cage • Press Hardened, integral A-Plr and B-Plr reinforcements • Press hardened roof bow and front header for load
transfer • Load achieved: >4.5 x GVW
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Safety Performance Summary
www.iihs.org
2017 Chrysler Pacifica Minivan
Crashworthiness Small overlap front Moderate overlap front Side Roof strength Head restraints & seats
G G G G G
With optional equipment
CRASH AVOIDANCE & MITIGATION
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NVH – Torsion Mode
Multi-Ring Body Structure Concept • Front End Module • +Shock Tower / Plenum / Cradle • B-Plr / C-Plr / D-Plr
D-Ring Structure Optimization • Structural insert in Upper D-Plr
• +1.3 Hz and 2.7 kg saved per vehicle • Improved shake performance
26.9 29.2 30.5
24
26
28
30
32
Town & Country PACIFICA w/oD-Plr Inserts
PACIFICAFr
eque
ncy
(Hz)
1st BIW Torsion Mode
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Competitive Body Torsional Stiffness
Lightweight Index Body in White Mass (kg)
Area (m2) x Torsional Stiffness (kN-m/deg)
12.2
22.9
0
5
10
15
20
25
Town & Country PACIFICA
Tors
ion
Stiff
ness
(kN
m/o
)
Torsion Stiffness
#GDIS | #SteelMatters 40 ©2016-17 FCA US LLC
NVH – Vertical Bending
Improved Body Bending Rigidity • Continuous rail loadpaths • Minimized upperbody breathing • Strategic placement of modal nodes
32.2 37.6
28
32
36
40
Town & Country PACIFICA
Freq
uenc
y (H
z)
BIW 1st Bending Mode
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Vertical Bending Response
Competitor A Town & Country
Improved Body Bending Rigidity • Reduced excitation of body structure to P/T, Chassis
vibration inputs • Improved ride and shake performance • Advanced topology-based stiffness optimization techniques
targeted strategic areas for modeshape improvement
PACIFICA
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NVH/Dynamics – Lateral Bending
Multi-ring body structure concept • Continuous, multi-plane ring structure
• Bolt-in FEM-load beam braces
• Solid-mounted cradle for improved isolation, front end stiffness and vehicle dynamics
FEM-Load Beam Brace
40 44.8 47
36
40
44
48
Town & Country PACIFICAw/o Braces
PACIFICAFreq
uenc
y (H
z)
BIW Lateral Mode
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NVH – Local Attachment Stiffness
Significant stiffness improvement at key noise and vibration input points
• Engine Mounts
• Trailing Arm Attachment
+250%
+85%
100 150 200 250 300 350 400 Frequency (Hz)
100 150 200 250 300 350 400 Frequency (Hz)
#GDIS | #SteelMatters 44 ©2016-17 FCA US LLC
Press Reviews It’s certainly the best minivan I’ve driven, but it might be better than a number of popular crossovers too. James Derek Sapienza – Autos Cheat Sheet
The suite of safety features seamlessly picked up where my mirrors and windows left off, and the big V6 moved the 4,350-pound van well enough to not leave me wanting for anything when accelerating for lane changes and stop lights. James Derek Sapienza – Autos Cheat Sheet
Riding on an all-new platform with 22 percent more high-strength steel and close to 130 meters of structural adhesives—thus boasting a 68 percent increase in stiffness—the Pacifica proved as solid as it did quiet. No squeaks or rattles and minimal wind and road noise. – Ron Kino - Motortrend
At an estimated 4,300 pounds, the Pacifica is about 250 pounds lighter than the old Town & Country. Credit the weight loss to the bump in high-strength steel, not to mention the introduction of aluminum sliding doors and an aluminum-magnesium liftgate. Ron Kino - Motortrend
Slapping aggressive price tags on a minivan is one thing. Backing it up with best-in-class performance and functionality is another. With Pacifica, Chrysler has successfully managed to do both. And it has sculpted what is for all intents and purposes a box into a sleek, sexy benchmark of style. Ron Kino - Motortrend
No, minivans aren't cool, but the 2017 Chrysler Pacifica is close – Antuan Goodwin – Road Show by CNET It also looks like a spaceship mated with a Ninja Turtle when
viewed from straight on. This kind of funky, kind of cool look adds to the Pacifica's curb appeal, I think. Antuan Goodwin – Road Show by CNET
All-new 2017 Chrysler Pacifica Named to Wards 10 Best Interiors List for
2016
“You guys remember, ‘Get Shorty,’ right?...It’s cool driving a minivan.” President Barack Obama - NAIAS
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#GDIS | #SteelMatters 46 ©2016-17 FCA US LLC
For More Information
James Truskin Technical Fellow Body Adv. Architecture Fiat Chrysler Automobiles US LLC
Jeff Tibbenham System Responsible BIW Fiat Chrysler Automobiles US LLC
Presentations will be available May 22 at www.autosteel.org