w w w . a u t o s t e e l .

o r g

Great Designs in Steel is Sponsored by:

AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
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LIGHTWEIGHTING AUTOMOTIVE BODY – ENABLERS
AND MANUFACTURING CHALLENGES
Daniel J. Grieshaber
General Motors

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 Outline

• Drivers
• Enablers
• Manufacturing Challenges
• Summary

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 Drivers for Lightweighting

Consumer Requirements
Cost
Quality
Performance + Features
Fuel Economy

Balance

Government Regulations Competitive Pressures

CAFE/CO2 Manufacturability
Crash Performance Cost, Quality, Performance
Emissions Fuel Economy

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 U.S. CAFE Standards
Ref. US Dept of Transportation, NHTSA, April 1, 2010

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 Enablers
Product Design Optimization

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 Integration of Efficient Load Paths

Based on Front ODB, NCAP, side impact and side pole requirements
from SID‐IIS and IIHS, tunnel and rail shapes are straightened.

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 Efficient Size and Shape

‐ Based on strain maps, “unloaded metal” at the lower portion of the

bracket was removed in final design.
‐ Removed metal was beyond original weld pattern.
‐ Tighter and fewer welds needed.

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Design Iteration of Geometry

From Bending
to Shear Joint

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 Local Reinforcement Strategy
(including Laser Welded Blanks and inserts)

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Lightening Holes and Scalloping

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 Thinnest Possible Part Gauges

Best practice gauge and grade templates are used to drive designs.

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 Material & Design Impact on Lightweighting

Increased Usage
of AHSS Improved Design
through Efficient:
•Load Path
•Joint Design
•Part Size/Geometry
•Material Gauge

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 Enablers
Light weight Materials

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 North American Body Material Trends
Body and Closure Metallic Material Content by Type

2007 2015
Aluminum & Aluminum &
Advanced Magnesium Magnesium
HSS Advanced
Conventional Mild Steel
HSS
HSS

Mild Steel
Bake Hardenable &
Medium HSS Conventional Bake Hardenable &
HSS Medium HSS

850 Pounds 800 Pounds with an Equal

Footprint to 2007
Source: Ducker Worldwide

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 Dual Phase Steel Part Applications
Vehicle Components
• Front Structure
• Passenger Compartment & Side Structure
• Upper Structure
• Rear Structure DP Mild

DP HSLA

Underbody Applications DP

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Manufacturing Challenges

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 Springback Management

Why:
• Still re-cutting dies – getting better, but
not there yet
• Dimensional requirements getting tighter

Topics:
• Springback reduction and management
through part and process design
• Springback prediction

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 Effect of Beads on Springback

• Beads can
significantly reduce 20

sidewall springback With Beads

Without Beads

Wall Opening Angle (degrees)

15

10

0
340LA DP600 DP750 TRIP800 DP980

-5
Material

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 Effect of 4-break Lock Flange on Sidewall Curl

• Springback
and sidewall
curl can be
reduced
through wall
stretching
enabled by 4-
break lock
flange

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Effect of 4-break Lock Flange on Springback

16.0
4 Break Lock Flange
14.0 Short Blank
Wall Opening Angle (Degrees)

12.0

10.0

8.0

6.0

4.0

2.0

0.0
340LA 590R DP600 DP750 TRIP800 DP980
Material

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 Rocker Example – Material Change

Material Change: CR900T/700Y-MS to CR980T/700Y-MP-LCE

Advantages Disadvantages

• Greatly Improved Shape Control • Higher Cost Compared to CR

• Significantly Improved Part Martensite
Dimensional Tolerances
• Improved Global Availability

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Rocker Example – Material Change

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 Dimensional Control

Design /
Geometry: Material
•Panel thickness Properties:
•Radii •Yield Strength
•Depth of draw •Tensile Strength
•Product features •Accurate Models
•Variability

Requirement
= +/- 0.5mm
Other:
•Shear Fracture

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 A/SP Tribology Project
•High loads require stronger
materials
- Cast steel displacing cast iron
- Increased use of tool steel inserts
and details
1.2 mm DP980 on Caldie Trim Insert
- Advanced coatings displacing chrome
plating
Plasma nitride
CVD, PVD, TD VC

•Guidelines under development

– Form, flange, trim, and pierce

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 Die Materials & Surface Treatments
Under Evaluation
Substrates
• S7, D2
• Vanadis ® 4E
• Carmo®
Carmo with PVD CrN, 65,000 hits
• Caldie™ Surface Treatments
• M2 • CVD TiC
• M4 • PVD CrN, TiCN, TiAlN
• Ion Nitride with CrN
• Chrome Plating

D2 Insert, 100,000 hits

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 Impact of Manufacturing Challenges
Manufacturing
Challenges:
•Springback /
Dimensional Control
•Press Tonnage
•Die Wear, Galling,
Burrs, etc.
•Joining
Known
Manufacturing
Processes
(current
infrastructure)

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 Summary
Increased
• Enablers Usage of
AHSS
Improved Design
through Efficient:
•Load Path
− Efficient Designs •Joint Design
•Part Size/Geometry
•Material Gauge
− Effective Use of
Advanced High Strength
Steel
Manufacturing
Challenges:
•Springback /
• Manufacturing Challenges Dimensional Control
•Press Tonnage
•Die Wear, Galling,
− Springback Prediction & Burrs, etc.
•Joining
Management
− Tool Design & Known Manufacturing
Maintenance Processes
(current infrastructure)

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 Challenges for Suppliers

• Availability of Advanced High Strength Steels

– grades, coatings, gauges, and coil widths

• Accurate Springback Prediction Tools

• Improved Die Materials & Surface Treatments

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 w w w . a u t o s t e e l . o r g

Great Designs in Steel is Sponsored by:

AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
www.autosteel.org