1. 7/30/2015
Raheim R Binnie
Product Development BIW Structures
Graduation date: December 2017
Mechanical Engineering Undergraduate
Project Overview

2. 27/30/2015
 Grosse Pointe North High School
 TV Series Binge Watcher
 Chapter President, NSBE
 First Official Internship
 Leadership Development: “If ‘Plan A’ didn’t work stay cool!”
PERSONAL BACKGROUND
BIW Structures

3. THE JOURNEY:
SAFETY & EFFICIENCY
3
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4. 47/30/2015
 Primary Project Objective: Joint Stiffness
Design Improvements
• Stiff body joints are crucial to utilize the full
strength of the connecting pillars.
• Weak joints cost time, money and often
add weight to the vehicle (CAFÉ)
 Establish joint stiffness targets for WN
and WS with the use of WK geometry.
 Enhance understanding of the joint
stiffness methodology.
 Benchmarking Competing Joints.
 Crash Testing Context Projects.
WK PROJECT BACKGROUND & GOALS
BIW Structures

5. 5
 Tool Overview:
• Current tool is an Altair HyperWorks
template which seeks to automate most
of the joint FEA process.
• HyperWorks works-pre and post
processor used to build, analyze and
review.
• The new Hyperworks suite has been
released.
 Allows for use of NX geometry.
 Compatible with weld and
adhesive weld files.
PRIMARY PROJECT TOOL
7/30/2015BIW Structures

6. 67/30/2015
ANALYSIS PROCEDURE?
• Process Summary:
 Import and convert geometry to
Finite Elements Analysis.
 Update criteria and parameter
standards to reflect the “real world”
joint.
 Perform manual (no templates) FEA
on all WK BIW joints to capture
baseline and note changes in
efficiency.
BIW Structures

7. 77/30/2015BIW Structures
 Extracted and organized
stiffness of individual WK BIW
joints for next generation
targeting.
 Upper B-Pillar Geometry
Improvements upwards of
200% in Stiffness.
RESULTS & IMPROVEMENTS
1
23
4

8. 87/30/2015
 Lead NVH joint testing of WK and
competitive Joint (Cadillac CTS and the
BMW) Analysis.
 Collaborate with NVH, Metrology and
Sheet-metal Labs for validation and
oversight.
 Correlate test to FEA Analysis model
 Recommendations:
● Consider implications behind
benchmarking.
BENCHMARKED STIFFNESS STUDIES
BIW Structures

9. THE BIG PICTURE?
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10. 107/30/2015
 Learn various FMVSS, NCAP, and IIHS test
setups and scoring criteria.
● The IIHS is an independent, nonprofit
scientific and educational organization
dedicated to reducing the losses — deaths,
injuries and property damage — from crashes
on the nation's roads.
 Participate in component and full vehicle
impact test.
● Pickups and SUVs generally are heavier than
cars, so occupant deaths in SUVs and
pickups are less likely to occur in multiple-
vehicle crashes – Vehicle Light-weighting.
IIHS IMPACT & DURABILITY TESTING
BIW Structures

11. 117/30/2015
 Participate in various vehicle level impact
tests.
 Developing understanding
crashworthiness of vehicles.
 Walk-through vehicle impact best
practices.
 Analyze seat-belt pull test results.
 Roof crush testing requirements &
details.
VEHICLE IMPACT PROJECT RESULTS
BIW Structures

12. MEANING?
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13. 137/30/2015BIW Structures
 Gained appreciation for the tests used to
determine the crashworthiness of FCA vehicles.
 Greatly increased understand of plant
environment and importance of the innovations
brought forth by World Class Manufacturing
(WCM).
 Finite Element Analysis capabilities associated
with the use of HyperWorks, NX and
TeamCenter.
 Professional Wherewithal necessary to design
and develop effective presentation and
technical communications.
KEY TAKEAWAYS

14. 147/30/2015
THE FUTURE
 Community & Diversity Advancement
Programs.
 Chrysler Leadership Development Program.
 The chance to learn about managing people.
 Round out my education.
 The skillsets necessary to become a leader in
an emerging field.
 A holistic perspective over both the
engineering and business world.
 Global Engineering Leader and Influencer.
 We must continue embracing change and
taking on risk and adventure. –Sergio
Marchionne
BIW Structures

15. Raheim Richard Binnie
Mechanical Engineering Undergraduate
Future Engineering Leader
Auburn Hills, MI
7/30/2015
THANK YOU