Automotive Door Design Amp Structural Optimization Of Front -Free Books

Automotive Door Design amp Structural Optimization of Front
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Automotive Door Design Structural,Optimization of Front Door for Commercial. Vehicle with ULSAB Concept for Cost and,Weight Reduction. Mr Sandeep Bundele Dr Mrs Rupa S Bindu, Abstract This research papers describes the drawbacks of which is not costly and recyclable Lightweight steel can. existing automotive door structure and suggest design be achieved by improving the performance of the. changes to overcome the present drawbacks This research. structure or adopting new manufacturing techniques 25. paper details out the analysis of the existing structure and. identifies the drawbacks and explains the process of door One of the efforts is the ULSAB ultra light steel. system design Changes required can be found out with autobody concept ULSAB suggests three main weight. Global Journal of Researches in Engineering B Volume XII Issue II Version I. correct method as explained in this paper Validation of the reduction techniques such as hydro forming and the. design parameters is of vital importance so the way by which tailor welded blank TWB In this research the TWB. validation of newly designed or modified parts can be done is technique is utilized for lightweight door design and a. briefly explained in this paper Designer from an automobile design process is proposed for optimizing the. engineer faces so many different problems during their work automobile TWB door In the automotive door assembly. Some of the major problems in automobile door are taken as door inner panel is divided into different thickness. problem for this research paper and those problems like high. without reinforcement components and different, weight high cost excessive reinforcements and water. leakage At first theoretically study of the existing system is thickness sheets plates are assembled by laser. done After that deciding the key areas of modification is the welding The use of tailored steel solutions eliminates. flow of this paper After finding the modification areas we tried the need for additional reinforcements and overlapping. some parameters for calculation On the basis of calculations joints in the body saving material and further reducing. the design of new parts are finalized Then 3D models are total weight In this way tailored blanks are a significant. prepared in CATIA V5 which are used for analysis purpose enabler to meet specified CO2 targets Reducing the. Finally on the basis of analysis results actual metal parts are weight of a car reduces CO2 emissions Objective of. developed in the proto shop and fitment trials are taken on the this paper is Low cost door design for developing. vehicle Once the fitment trial is completed actual testing is. countries India Srilanka South Africa without, done on the vehicle Comparing those results with the old.
results the improvement is suggested during this study some compromising any performance and regulatory. specific parameters are chosen for observation and requirements for example removing molded trim with. improvement On the basis of these results final design is hard pad cost saving approximately 1400 Rs set. frizzed Reducing the weight of door assembly by reducing. Keywords ULSAB Concept Problems in TWB number of components and by using advance. technology new inner panel for hardpad water leakage technologies like tailor welded blank and high strength. issue material Existing design has a water leakage problem. from the assembly of inner door panel and seal because. I Introduction of different thickness of inner panel The parts which are. ecently there have been two approaches in newly designed or modified are designed on the basis. reducing automobile weight One is by using of space constrained The main constrained is that. material lighter than steel and the other is by avoids as much as modification in the machined parts. redesigning the steel structure Although the, former seems very effective it is very expensive so that it. may only be used for an expensive automobile, Therefore the automobile industry is trying to use steel. Author Student M E Design D Y Patil college of engineering. Akurdi Pune E mail Sandeep bundele yahoo com, Author Prof and Head Department of Mechanical engineering. D Y Patil college of engineering Akurdi Pune,E mail rsbindu31 rediffmail com. 2012 Global Journals Inc US, Automotive Door Design Structural Optimization of Front Door for Commercial Vehicle with ULSAB.
Concept for Cost and Weight Reduction, II Exsisting Inner Door Panel Design a Material used for exsisting inner door panel. 0 7mm thick EDD 513 1 6mm thick St40e,Table 1 For material properties. Grade St 35E Grade St 40E,Carbon 30 PPM max 30 PPM max. Mangnese 0 35 0 45 0 35 0 45,Sulphur 0 010 max 0 010 max. Phosphorus 0 06 max 0 06 max,Silicon 0 015 max 0 015 max.
Alumini 0 02 0 04 0 02 0 04,Titanium 0 015 0 025 0 015 0 025. Niobium 0 035 0 045 0 035 0 045,Boron 5 10 PPM 5 10 PPM. Grade St 35E Grade St 40E,Fig 1 Front Door Inner Panel Weight 6 3 kg. Global Journal of Researches in Engineering B Volume XII Issue II Version I. Yield 180 220 MPa 230 270 MPa, Inner door panel is a component which is use Strength. for strengthening the door assembly and it is one of the Tensile 345 386 MPa 390 MPa min. most important components on witch all accessories are Strength. mount like hinges glass guide channel Front door sill Elongation 35 min 34 min. window winding regulator hard pad molded trim latch. etc Front door inner panel is use for sealing purpose R 1 6 1 9 1 5 1 9. when the primary sill is mounted on this The weight of. Door inner panel is near about 7to8kg depends upon its N 0 21 0 24 0 20 0 24. material and its thickness The possible method is the. integration method In the integration method the part is. III Design Of New Door Inner Panel For, stamped out of a single blank This reduces the number.
of tools needed the assembly cost and eliminates any Reducing Cost And Weight Of Front. fit ability problem However the design engineer is Door Assy. forced to work with same grade thickness and, corrosion resistance throughout the entire part Since In this paper we are going to reduce weight of a. the most demanding of all these conditions must be front door assembly by using tailor welded blank. satisfied for the entire blank this would increase the cost concept for front door inner panel and using less. and weight of the part thickness high strength material and reducing cost by. replacing molded trim with hard pad in front door,assembly and saving 1400 Rs set. a Methods of preparing inner door panel,1 In current automotive stamping technology there. are two basic paths that can be followed to arrive at. the final inner door panel The first method is part. disintegration or part separation In this technique. each different section of the blank is stamped,separately and then spot welded together in the. shape of the final part This method has numerous, advantages such as the ability to select the specific.
properties i e the strength thickness corrosion,resistance etc of each area of the blank This. method also gives a higher yield ratio of,materialused. 2 The other possible method is the integration,method In the integration method the part is. Fig 2 Assembly of molded trim and with inner panel stamped out of a single blank This reduces the. 2012 Global Journals Inc US, Automotive Door Design Structural Optimization of Front Door for Commercial Vehicle with ULSAB. Concept for Cost and Weight Reduction,number of tools needed the assembly cost and.
eliminates any fit ability problem However the,design engineer is forced to work with same grade. thickness and corrosion resistance throughout the,entire part Since the most demanding of all these. conditions must be satisfied for the entire blank this. would increase the cost and weight of the part,significantly. 3 A solution to the problems listed above is the, utilization of tailor welded blanks A tailor welded. blank is a blank that is comprised of two separate. pieces of sheet metal that has been welded, together previous to stamping Tailor welded blanks.
allow the welding of the different grades different. thickness or different corrosion coatings together in. order give the properties needed in different areas. without increasing the number of tools needed to 27. form the part and eliminating the fit ability concerns. They also allow a high degree of flexibility in Fig 3 Significance of ribs and beads. Global Journal of Researches in Engineering B Volume XII Issue II Version I. designing parts and large blanks can be formed, from much smaller sheets The use of tailor welded c Material used for new door inner panel. blanks would reduce the weight of the car Having 0 7mm thick EDD 513 1 2mm thick DP590. the ability to selectively place different thickness of. material would result in weight reductions An Table 2 For material properties. example of this used in production is the door inner. panel The only strength requirement on a door Element DP 590. inner is in the region where the hinges attach to the Carbon 0 08 0 12. panel Manganese 1 1 1 6,Sulphur 0 004 max, b Design guidelines for designing door inner panel P 0 02 max. Yield Strength 350min MPa,Tensile Strength 590min MPa. Elongation 24 min, d Design of new door inner panel for solving water. leakage issue,Tailor Welded Blanks are made from individual.
steel sheets of different thickness strength and coating. which are joined together by laser welding When we. design inner door panel with tailor welded blank in witch. some portion of a panel having different thickness and. other is different In our case some portion of door inner. panel is 0 7mm thick shown below with pink color and. another is 1 2mm thick shown below with sky color, There is a 0 5mm gap between these two thicknesses. and this is the reason that water is leakage between. door inner panel and secondary sill in shower test. Beads and ribs increases the cross sectional Below figures gives the idea of existing and new. area of component and load taking capacity increases coditions. By adding beads we are able to reduce spring back,effect of component. 2012 Global Journals Inc US, Automotive Door Design Structural Optimization of Front Door for Commercial Vehicle with ULSAB. Year 2012 Concept for Cost and Weight Reduction, Global Journal of Researches in Engineering B Volume XII Issue II Version I. Fig 6 New front door inner panel, Fig 4 Existing inner door panel condition with inside.
Fig 5 New inner door panel condition with outside,New front door inner panel for hardpad no water. leakage issue weight 5 9kg Fig 7 Assembly of new door inner panel hard pad. IV Forming Analysis,The technique of sheet metal forming analysis. requires non contact optical 3D deformation measuring. system The system analyzes calculates and,documents deformations of sheet metal parts for. example It provides the 3D coordinates of the, component s surface as well as the distribution of major. and minor strain on the surface and the material, thickness reduction In the Forming Limit Diagram the.
measured deformations are compared to the material. characteristics The system supports optimization,2012 Global Journals Inc US. Automotive Door Design Structural Optimization of Front Door for Commercial Vehicle with ULSAB. Concept for Cost and Weight Reduction, processes in sheet metal forming by means of Fast V Cae Analysis. detection of critical deformation areas Solving complex. forming problems The optical forming analysis with To evaluate the stiffness and sag performance. forming analysis system provides for precise and fast of the front door for both existing and hard pad Different. measurement of small and large components using a stiffness s considered for front door assemblies are The. high scanning density Forming analysis system objective of this analysis is to predict the vertical sag. operates independently of the material It can analyze behavior of the front door assembly of CUB Goods. components made from flat blanks tubes or other Carrier As per the procedure there should not be a. components manufactured by an internal high pressure permanent set exceeding 1 mm and maximum latch. forming process Hydro forming The Forming limit point deflection elastic should not be more than 10. curve is used in sheet metal forming for predicting mm At the latch point under two conditions. forming behavior of sheet metal The diagram attempts. to provide a graphical description of material failure Table 3 Boundary and Load conditions. tests In order to determine whether a given region has. failed a mechanical test is performed The mechanical Location Load Cases Force. test is performed by placing a circular mark on the work No. 2 Torsional An inboard force 1000N is, piece prior to deformation and then measuring the 29. rigidity top applied to the door inner, post deformation ellipse that is generated from the corner top. action on this circle 3 Torsional An inboard force 1000N is. Global Journal of Researches in Engineering B Volume XII Issue II Version I. rigidity bottom applied to the door inner,corner bottom.
4 Beltline inner A horizontal force of 600N is,applied to the beltline. reinforcement at the midpoint,of the window opening inner. 5 Beltline outer A horizontal force of 600N is,applied to the beltline. reinforcement at the midpoint,of the window opening outer. Stiffness Analysis, 1 Predicted vertical stiffness of door with hard pad.
interiors is lower than existing front door design. 2 Predicted beltline inner stiffness of door with hard. pad interiors is lower than existing front door design. 3 Predicted beltline outer stiffness of door with hard. pad interiors CAE Proposed design is equivalent, Fig 8 Color bands in forming limit dig to existing front door design. Door Sag Analysis,Predicted maximum elastic deflection and. permanent set in door under worst door sag load case. are as follows,1 Existing design Maximum elastic deflection is. 7 75mm and permanent set is 0 23,2 Hard pad design Maximum elastic deflection is. 9 27mm and permanent set is 0 34,VI Conclusion,In this paper we design new front door.
assembly components with tailor welded blank,technology for reducing weight and cost of door. assembly Tailor welded blanks allow combining, different strengths of steel in one part without adding. Fig 9 Inner panel in safety zone complications at the joints Weight of a door assembly is. 2012 Global Journals Inc US, Automotive Door Design Structural Optimization of Front Door for Commercial Vehicle with ULSAB. Concept for Cost and Weight Reduction, reducing by 0 4 kg by reducing weight of a door inner. panel by using less thickness high strength material. reduce cost by replacing molded trim with hard pad We. are successfully solved water leakage problem by,modeling front door inner panel correctly.
References R f rences Referencias,1 New methods for forming Tailor welded blanks. Date published 1999 03 01 Paper no 1999 01,0681 DOI 10 427 1999 01 0681 By Brad Kinsey. 2 Formability Issues in the Application of Tailor,Welded Blank Sheets Date Published 1993 03 01. Paper Number 930278 DOI 10 4271 930278 by,Ming F Shi National Steel Corp Ken M Pickett. 30 National Steel Corp Kumar K Bhatt General,Motors Corp.
3 Describing the formability of tailor welded blanks. Global Journal of Researches in Engineering B Volume XII Issue II Version I. Date Published 2002 01 2085 By Rich Davies and,Mark Smith. 4 The Stiffness of Automobile Inner Panels Date,Published 1987 11 08 PaperNumber 871294 DOI. 10 4271 871294 by Toshiaki Sakurai Mitsubishi,Motors Corp Hiroyuki Ono Mitsubishi Motors. 5 E Balmuth Steel alloy for thick section,applications presented at TMS AIME meeting at. Denver co February 1993, 6 The development of vibration damping steel sheets.
for inner panels of Automotive Vehicles Paper no,911083 By Toshiaki Shiota Hiroyuki Nagai. 7 Laser Welding of Advanced High Strength Steels for. Tailor Welded Blank TWB Applications Date,Published 2009 12 13 Paper Number 2009 28. 0012 DOI 10 4271 2009 28 0012 by,B Shanmugarajan ARCI J K Sarin Sundar ARCI. G Padmanabham ARCI,8 Integrated Inner Door Panel Energy Absorber. Designs for Side Impact Occupation Protection,Date Published February 26 29 1996 Paper.
Number 960151 by Luis Lorenzo Scott Burr and,Karen Fennessy Ketola Dow Chemical Co. 9 Door System Design for Improved Closure Sound,Quality Date Published 1999 05 17 Paper Number. 1999 01 1681 DOI 10 4271 1999 01 1681 by A,Petniunas Ford Motor Co N C Otto Ford Motor. Co S Amman FordMotorCo R Simpson Ford, 10 Development of Lightweight Door Intrusion Beams. Utilizing an Ultra High Strength Steel Date,Published 1975 02 01 Paper Number 750222.
DOI 10 4271 750222 T E Fine Inland Steel Co,S Dinda Chrysler Corp.


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