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Automotive Steel Design Manual

Automotive Steel Design Manual

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Published by: vinu198500 on Mar 27, 2010
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This section provides case studies that illustrate the application of the principles inSections 2, 3and4to vehicle components. Note that some of the case studies utilize results from CARS 2000.The associated GAS cross section files and KEY Design Procedure files are included with theCARS program for CARSusers to review. Some case studies have a corresponding tutorial inSection 7.2.Table 6.1-1lists the case studies and CARS 2000 program(s), if applicable.
Table 6.1-1
Case Studies
SectionCase StudyCARS ProgramTutorial
6.1.1Uniside construction6.1.2Front shock tower construction6.1.3Hood inner panel6.1.4Door anti-flutter bar using engineered scrap6.1.5Modular seat support6.1.6Design of an anti-intrusion door beamGAS6.1.7Design of a front railGAS, KEY, MAPSection 7.2.1
6.1.1 UNISIDE CONSTRUCTION6.1.1.1 Introduction
The designer frequently finds opportunity to reduce the number of pieces that make up majorbody assemblies. In many cases, he can assess the alternatives and combine two or three smalldetails, if warranted, with only minor design changes to accommodate tooling. For majorassemblies the decision can become quite complex, requiring detailed studies for uppermanagement deliberation.A typical approach is to establish the design with the greatest number of pieces as a baseline anda set of alternatives. Advantages and disadvantages of each are identified, and dollar valuesassigned.The following case study was extracted from an actual design program. It illustrates theapproach used to assess the many factors involved in the one-piece versus multi-piece options of a major assembly, the body side. The dollar values generated are unique to the internalcircumstances; they have no quantitative significance outside of the environment in which thestudy was made. They are included in this study to reflect the relative values that were assignedto the various factors involved in the decision. Definition
This case study assesses three design alternatives for the body side assembly: uniside, two-pieceand multi-piece. Uniside is a one-piece body side panel that includes the outer A pillar, outerroof rail, rocker panel, outer B pillar, quarter lock pillar, and quarter panel. Two-piececonstruction incorporates the same components into two major panels, the door opening paneland quarter panels. For the multi-piece, the components listed above are separate details, weldedtogether to form the body sideassembly. The three types of construction are shownschematically in Figure
Page 6.1-2AUTOMOTIVE STEEL DESIGN MANUALMay 1996Section 6.1 Case StudiesAPPLICATIONSA survey of existing cars in the early 80's (see Table that there is no clear-cut  preference among manufacturers for any of the three alternatives.
Body side construction
Sample of construction type usage
UnisideTwo PieceMulti PieceOpel KadetteFord European ScorpioAudi 100Fiat UNOFord North American DN5 and FN9Mercedes 190Chrysler K carsToyota TercelNissan MicraG. M. 4 door J carsVW PassatMitsubishi GalantFiat StradaOpel RekordG. M. 2 door J CarsVW GolfRenault R5, R9, R11Toyota (most models)Honda (most models)Ford North American (most models)Ford European (except Scorpio)Mazda (most models)Mazda RX7 and BT17 Analysis
Relevant Factors
Many factors must be considered to determine the appropriate type of construction for a particular vehicle. Replacing the several stampings that make up the body side assembly withone or two major panels (uniside or two-piece) will:1. Require larger press capacity.2. Increase shipping, handling, and storage costs, depending on the nearness of stampingfacility to assembly facility.
April 1998AUTOMOTIVE STEEL DESIGN MANUALPage 6.1-3APPLICATIONSSection 6.1 Case Studies3. Limit interchangeability between models.4. Increase the cost of model-year face lifts.5. Prohibit the selective use of material gauges, coatings, and strengths, or requires tailorwelded blanks.6. Produce more offal.7. Limit the depth of draw, die tip angle, and door opening corner radii, reducing stylingflexibility.8. Adversely affect serviceability. Partial service repair panels must be cut from uniformside panels and stocked for collision damage repair.9. Affect mass, noise, vibration, and harshness due to joint elimination.10. Tend to reduce mass by eliminating weld joints with overlapping metal. The tendencymay be offset by the reduced flexibility in metal gauge.11. Improve door/body margin control requirements and surface flushness.12. Improve door/body sealing and reduce wind noise.13. Increase customer quality appeal due to the clean, no joint appearance.14. Improve first-run capability at assembly plant.15. Improve fatigue life expectancy
Concepts and Alternatives
Eighteen (18) design concepts, designated with the letters A through Q and defined in Table6.1.1.3-1, were weighed (there are two variations of H and L, and no I).
Concepts A through Q defined
Construction TypeSedanStation WagonRemarksCommon DoorsUnique DoorsMulti PieceA(Base)GK (Base)UnisideBNQTwo PieceCHLQuarter assembled to body atassembly plantTwo PieceDHLQuarter assembled to body atstamping plantTwo piece body openingquarter lock pillar integral w/ quarter panelEJMMulti piece upgraded quarterlock pillar integral w/ quarterFOP

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