FutureSteelVehicle Design Methodology: Detail Design Concept using 3G Optimization 2012-01-1345

As worldwide demand for affordable, safe and low greenhouse gas emission vehicles surged, WorldAutoSteel launched the FutureSteelVehicle program (FSV) aimed at helping automakers optimize body structures through advanced steel design concepts suitable for both conventional and electrified powertrains. The objective was to develop detailed design concepts and fully optimize a radically different body structure vehicle in production in 2015-2020 timeframe utilizing the latest grades of advanced and ultra-high strength steels. FSV achieved 35 percent mass reduction [approaching aluminum body structure mass with similar performance], at no additional cost over a conventional steel body while achieving simulated crash test performance enabling a 5-star safety rating. This was accomplished with a portfolio of 34 standard and advanced steel grades and 17 steel manufacturing technologies together with a state-of-the-future design methodology. The body structure contained 97 percent high-strength and advanced high-strength steel (HSS & AHSS) with 44 percent of these in the GigaPascal strength range.

FutureSteelVehicle Design Methodology is a product design optimization methodology that has been developed by Engineering Technology Associates, Inc., (ETA) and WorldAutoSteel into ETA's Accelerated Concept to Product (ACP) Process™ utilizing the latest steel grades available by 2015 and the latest in manufacturing processes to achieve a 35% BIW mass reduction while achieving all vehicle performance targets at an early design concept level.

The FutureSteelVehicle Design Methodology creates many design solutions and options. This paper provides an insight to the de-coupling process of the vehicle to subsystem (components) models and the optimization process that allows designing components into diverse, non-intuitive shapes that could follow nature and organic shapes. The paper examines 10 potential design solutions out of 537 designs for the front longitudinal rail sub-system and reports their results. The study shows the many design solutions that are available utilizing different gauges, grades, geometries and various manufacturing techniques while still meeting all of the design requirements.