Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith...
Transcript of Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith...
![Page 1: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/1.jpg)
w w w . a u t o s t e e l . o r g
Lightweight Steel Wheels
Offer Stylish, Low Cost Solutions
Timothy Smith
Altair ProductDesign, Inc.
![Page 2: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/2.jpg)
w w w . a u t o s t e e l . o r g
Project Introduction
• Develop a steel wheel architecture that:
• has equivalent mass to a target cast aluminum wheel
• is 30% lower in cost
• Is stylish in it baseline form
• Provides an aesthetic upgrade path through the addition of wheel trim
Goal:
Background: • Currently automotive wheels utilize materials and process that have been in use for
many years
• Light weight wheels being costly
• Lower cost wheels limit aesthetic freedom
• A stylish, lightweight, low cost steel wheel could increase market penetration
Method: • Let me take you through the method we applied to achieve this goal
![Page 3: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/3.jpg)
w w w . a u t o s t e e l . o r g
Baseline Wheel
GMC Terrain Alum Wheel 10kg (22lbs.)
Target Application
Chevy Malibu Steel Wheel 10.7 kg + 0.66 kg (cover) = 11.36 kg
23.6 lbs + 1.46 lbs (cover) = 25 lbs
Design Surrogate
![Page 4: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/4.jpg)
w w w . a u t o s t e e l . o r g
Wheel Performance
MALIBU
St Wheel
TERRAIN
Al Wheel Packaging / Mass Target
Strength / Stiffness Performance
10 kg = 22 lbs
10.7 kg + 0.66 kg (cover) = 11.36 kg
23.6 lbs + 1.46 lbs (cover) = 25 lbs
Strength / Stiffness Performance
(not available)
AISI
St Wheel
Note: Considering that there was no steel wheel option for the Terrain, it was necessary to select
an existing steel wheel design surrogate to serve as a suitable baseline reference
![Page 5: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/5.jpg)
w w w . a u t o s t e e l . o r g
Generic Illustration of Design Process
![Page 6: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/6.jpg)
w w w . a u t o s t e e l . o r g
Package Space Development
GMC Terrain Wheel End Package Space
![Page 7: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/7.jpg)
w w w . a u t o s t e e l . o r g
Terrain’s Package Space
Malibu Steel Wheel
Terrain vs. Malibu Pkg Space
![Page 8: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/8.jpg)
w w w . a u t o s t e e l . o r g
Based on GM’s input, 3 loading conditions were studied:
• Radial Load (13,690 N = 3,076 lbs)
• Lateral Load (impact) (5,415 N = 552 lbs)
• Bending (2,730 N.m = 3,592 N @760mm)
Wheel Load Cases
![Page 9: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/9.jpg)
w w w . a u t o s t e e l . o r g
Topology Optimization Results
![Page 10: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/10.jpg)
w w w . a u t o s t e e l . o r g
Topography Optimization Results
![Page 11: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/11.jpg)
w w w . a u t o s t e e l . o r g
Inspiration
![Page 12: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/12.jpg)
w w w . a u t o s t e e l . o r g
Design Evolution
The evolution of the “drop center” design based on performance
![Page 13: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/13.jpg)
w w w . a u t o s t e e l . o r g
Bead Seat Concept Selected
Bead Seat concept proved to be very efficient in terms of mass and
performance and became our primary concept
• Mass: ~10kg
• Stiffness/Strength Performance similar to Malibu steel wheel
![Page 14: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/14.jpg)
w w w . a u t o s t e e l . o r g
Comparison: Malibu Vs SMDI Design
Malibu
Radial Load Stress Contour (MPa)
Bead Seat Design
![Page 15: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/15.jpg)
w w w . a u t o s t e e l . o r g
Comparison: Malibu Vs SMDI Design
Malibu
Bending Load Stress Contour (MPa)
Bead Seat Design
![Page 16: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/16.jpg)
w w w . a u t o s t e e l . o r g
Alternate Constructions Evaluated
![Page 17: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/17.jpg)
w w w . a u t o s t e e l . o r g
Comparison: Malibu Vs SMDI Concepts
Radial Load Stress Contour (MPa)
Bead Seat Concept – 490Y
Between spoke locations
Malibu – 300Y (rim)
yield
yield
yield
yield
yield
yield
Full Face – 420Y
At spoke locations
![Page 18: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/18.jpg)
w w w . a u t o s t e e l . o r g
Comparison: Malibu Vs SMDI Concepts
Malibu – 300Y (rim)
Lateral Load Stress Contour (MPa)
Bead Seat – 490Y Full Face – 420 Y
yield 1.5x yield
yield 1.5x yield
yield 1.5x yield
yield 1.5x yield
yield 1.5x yield
yield 1.5x yield
![Page 19: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/19.jpg)
w w w . a u t o s t e e l . o r g
Comparison: Malibu Vs SMDI Concepts
Bending Load Stress Contour (MPa)
Malibu – 380Y (disc) Bead Seat – 490Y Full Face – 420Y
yield 1.5x yield
yield 1.5x yield
yield 1.5x yield
![Page 20: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/20.jpg)
w w w . a u t o s t e e l . o r g
Formability – One Step
Malibu 6mm
380Y
r = 1.0
n = 0.17
Bead Seat– 5.8mm
490Y
r = 1.0
n = 0.144
Full Face – 5.4 mm
420Y
r = 1.0
n = 0.158
Thinning comparison
![Page 21: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/21.jpg)
w w w . a u t o s t e e l . o r g
Formability – One Step
Malibu
380Y
r = 1.0 / n = 0.17
Bead Seat- 5.8 mm
490Y
r = 1.0 / n = 0.144
Full face – 5.4 mm
420Y
r = 1.0 / n = 0.158
FLD comparison
![Page 22: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/22.jpg)
w w w . a u t o s t e e l . o r g
Gauge Optimization Study
Tailor-welded parts configurations:
Thicknesses are color-coded
![Page 23: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/23.jpg)
w w w . a u t o s t e e l . o r g
Retained Designs
SMDI
Concept
Bead Seat
SMDI
Concept
Full Face
2.1mm
5.8mm
5.4mm 1.8mm
![Page 24: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/24.jpg)
w w w . a u t o s t e e l . o r g
Final Design
![Page 25: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/25.jpg)
w w w . a u t o s t e e l . o r g
Wheel Dress Ideas
![Page 26: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/26.jpg)
w w w . a u t o s t e e l . o r g
Thank you!
![Page 27: Timothy Smith - SRI - Steel Recycling Institute/media/Files/Autosteel/Great... · Timothy Smith Altair ProductDesign, Inc. w w w . a u t o s t e e l . o r g Project Introduction •Develop](https://reader034.fdocuments.us/reader034/viewer/2022042306/5ed2cbce9c95614861232f01/html5/thumbnails/27.jpg)
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