The document provides an overview of the development of the all-new 2016 Honda Civic. Key points include:
- The development goal was to create the best C-segment vehicle in the world.
- It had a global development team and is produced in 10 plants worldwide.
- The package aims to be low and wide with best-in-class interior volume.
- There are two new powertrains - a 1.5L turbo and 2.0L engine - that maximize performance and efficiency.
- Significant work went into improving crashworthiness, handling, noise reduction and fuel economy through changes to the body construction, chassis, and safety structures.
Full Frontal, 40% & 20% Offset Impact Analysis on Ford Econoline.Vaibhav porwal
Full Frontal, 40%, and 20% impact analysis of Ford Econoline using LS-PrePost and LS-DYNA, including front airbags, side curtain airbag and a seatbelted to reduce the fatal injuries.
What is a Chassis?
Different Types of Chassis
Ladder frame chassis
Tubular space frame chassis
Aluminum space frame
ULSAB Monocoque chassis
Back bone frame chassis
Introduction to Monocoque Design
What is Monocoque construction?
Where is this used?
Origin of Monocoque design
History of Monocoque Frame
Full Frontal, 40% & 20% Offset Impact Analysis on Ford Econoline.Vaibhav porwal
Full Frontal, 40%, and 20% impact analysis of Ford Econoline using LS-PrePost and LS-DYNA, including front airbags, side curtain airbag and a seatbelted to reduce the fatal injuries.
What is a Chassis?
Different Types of Chassis
Ladder frame chassis
Tubular space frame chassis
Aluminum space frame
ULSAB Monocoque chassis
Back bone frame chassis
Introduction to Monocoque Design
What is Monocoque construction?
Where is this used?
Origin of Monocoque design
History of Monocoque Frame
• PRODUCTIVIDAD
Alcanzar/mejorar los niveles de productividad de Toyota.
Aumentar la utilización de recursos.
Estandarizar las prácticas/procesos óptimos.
Sistema de producción Ford estandarizado.
• SATISFACCION DEL CLIENTE
Mayor sensibilidad hacia los clientes.
Decisiones rápidas e implementación ágil.”
Así, el objetivo que Ford Motor Company persigue es "producir mejores productos más rápidamente y a un precio más bajo para satisfacer a más clientes en todo el mundo". Para conseguirlo va a llevar a cabo un rediseño tanto de sus procesos como de su estructura, basando la misma en sus productos y no en las áreas geográficas, como venía actuando desde su creación.
“CONCEPT VALIDATION AND DESIGN SYNTHESIS OF CAR DASHBOARD AS PER PLASTIC TRIM...Jayesh Sarode
The evolution of dashboard has led to increased
vehicle occupant comfort and convenience as new systems
become available. The project work aims to develop the work
to apply theoretical and practical tools/techniques to solve
real life problems related to industry and current research in
this project automobile (Car) dashboard upper cover is
selected for a design. For doing so conceptual design tool is
used. I am created a five different concepts using different
benchmarking & brainstorming. Select a best option using
different tools in six sigma like trade off analysis. Threedimensional
CAD software (such as CATIA) is used to develop a
CAD model same as concept. The aim is to achieve the essential
function at the lowest overall cost while maintaining
customers’ optimum value assurance. In this project I try to
develop a such dashboard design which follow a design
guidelines, And analyze and discuss the results to Obtain valid
conclusions which follows a design Standards.
Rear Impact Analysis with a moving deformable barrier.Vaibhav porwal
Validation a rear impact analysis with a deformable moving barrier on an SUV car according to FMVSS 301. Optimized overall deformation of the vehicle to improve the rail model.
Developing Commercial Vehicles Inspired by NatureAltair
As Germany's largest independent engineering partner to the worldwide automotive industry, EDAG is continuously seeking for new technologies and innovative processes to streamline vehicle development. EDAG has a profound expertise in integrated development and the optimization of vehicles, production facilities, derivatives, and modules. To meet fuel efficiency and emission reduction goals, structurally efficient lightweight designs are demanded in the development of passenger cars and commercial vehicles alike. To fulfill customer demands and to deliver lighter and yet fully functional and validated components in shorter time, EDAG is leveraging its engineering knowledge to combine state-of-the-art computer aided engineering tools, in this case Altair's OptiStruct, with new production technologies such as additive manufacturing. OptiStruct enabled the EDAG engineers to design lightweight and, by being inspired by nature, yet stiff structures of a cabin and a chassis. The components were then manufactured using additive manufacturing methods. To find the optimal solution for the final design the engineers later also conducted multi-physical optimizations, combining strength and crash demands of the vehicle, using an equivalent linear approach. The entire development and manufacturing process for the cabin and chassis structures will be subject of this presentation, showing how a combination of topology optimization and additive manufacturing leads to lighter and stiffer products. The project is a prime example of how mature CAE technology can be adjusted and used in combination with new manufacturing methods to introduce revolutionary structural enhancements within the transportation sector.
Speakers
Andreas Pfeiffer, Development Engineer, EDAG
This presentation encompasses various strategies adopted by ferrari to make it a brand ,marketing strategies,strategic management and SWOT analysis and ansoff matrix for ferrari
• PRODUCTIVIDAD
Alcanzar/mejorar los niveles de productividad de Toyota.
Aumentar la utilización de recursos.
Estandarizar las prácticas/procesos óptimos.
Sistema de producción Ford estandarizado.
• SATISFACCION DEL CLIENTE
Mayor sensibilidad hacia los clientes.
Decisiones rápidas e implementación ágil.”
Así, el objetivo que Ford Motor Company persigue es "producir mejores productos más rápidamente y a un precio más bajo para satisfacer a más clientes en todo el mundo". Para conseguirlo va a llevar a cabo un rediseño tanto de sus procesos como de su estructura, basando la misma en sus productos y no en las áreas geográficas, como venía actuando desde su creación.
“CONCEPT VALIDATION AND DESIGN SYNTHESIS OF CAR DASHBOARD AS PER PLASTIC TRIM...Jayesh Sarode
The evolution of dashboard has led to increased
vehicle occupant comfort and convenience as new systems
become available. The project work aims to develop the work
to apply theoretical and practical tools/techniques to solve
real life problems related to industry and current research in
this project automobile (Car) dashboard upper cover is
selected for a design. For doing so conceptual design tool is
used. I am created a five different concepts using different
benchmarking & brainstorming. Select a best option using
different tools in six sigma like trade off analysis. Threedimensional
CAD software (such as CATIA) is used to develop a
CAD model same as concept. The aim is to achieve the essential
function at the lowest overall cost while maintaining
customers’ optimum value assurance. In this project I try to
develop a such dashboard design which follow a design
guidelines, And analyze and discuss the results to Obtain valid
conclusions which follows a design Standards.
Rear Impact Analysis with a moving deformable barrier.Vaibhav porwal
Validation a rear impact analysis with a deformable moving barrier on an SUV car according to FMVSS 301. Optimized overall deformation of the vehicle to improve the rail model.
Developing Commercial Vehicles Inspired by NatureAltair
As Germany's largest independent engineering partner to the worldwide automotive industry, EDAG is continuously seeking for new technologies and innovative processes to streamline vehicle development. EDAG has a profound expertise in integrated development and the optimization of vehicles, production facilities, derivatives, and modules. To meet fuel efficiency and emission reduction goals, structurally efficient lightweight designs are demanded in the development of passenger cars and commercial vehicles alike. To fulfill customer demands and to deliver lighter and yet fully functional and validated components in shorter time, EDAG is leveraging its engineering knowledge to combine state-of-the-art computer aided engineering tools, in this case Altair's OptiStruct, with new production technologies such as additive manufacturing. OptiStruct enabled the EDAG engineers to design lightweight and, by being inspired by nature, yet stiff structures of a cabin and a chassis. The components were then manufactured using additive manufacturing methods. To find the optimal solution for the final design the engineers later also conducted multi-physical optimizations, combining strength and crash demands of the vehicle, using an equivalent linear approach. The entire development and manufacturing process for the cabin and chassis structures will be subject of this presentation, showing how a combination of topology optimization and additive manufacturing leads to lighter and stiffer products. The project is a prime example of how mature CAE technology can be adjusted and used in combination with new manufacturing methods to introduce revolutionary structural enhancements within the transportation sector.
Speakers
Andreas Pfeiffer, Development Engineer, EDAG
This presentation encompasses various strategies adopted by ferrari to make it a brand ,marketing strategies,strategic management and SWOT analysis and ansoff matrix for ferrari
Design Thinking ist ein Mindset und baut vor allem auf die Interdisziplinarität eines Teams auf. Damit auch wirklich gute und umsetzbare Ideen herauskommen, hilft es, wenn für die gemeinsame Zusammenarbeit ein paar Richtlinien aufgestellt werden.
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
A preliminary design review slideshow for the electric endurance car, Mila. This was put together by the entire team and presented in the spring of 2019.
5. R&D Global Teamwork
South America
Asia & Oceania
Europe,
Middle East & Africa
China Japan North America
6. Global Production Locations
HAB
Brazil
WDHAC
China
Malaysia Vietnam
HTW
HACPL
Taiwan
HVNHMSB
Pakistan
Thailand
HATC
4D
4D
4D & 2D
HCM
Ontario
HMIN
Indiana
4D
HCM Global
Lead Plant
4D & 2D
HUM
England
5D
4D
Civic is produced at 10 assembly plants globally
– 2D, 4D, 5D variations
16. Performance Target
Previous NA
Mass Market Targets
European
PerformanceTargetsTARGET
Acceleration
Fuel Economy
Brakes
Handling
Safety
Noise, Vibration &
Harshness
Interior Quality
Stance
Interior & Cargo Volume
GOAL
G-feeling
Efficiency
Confidence & Security
Agility & Directness
Maximum protection
Refined Crusing
Premium Materials
Low & Wide Exterior
Superior Packaging
17. Dynamic Performance | Chassis Optimization
Independent Multilink Rear
Suspension & Rigid Mount Subframe
10” Master Power with Large
Diameter Master Cylinder
MacPherson Strut
Front Suspension
Dual Pinion Variable Ratio
Electric Power Steering
Low Friction Bearings & Brake
Calipers (Front & Rear)
Hydraulic Bushings
18. Agile & Direct Handling
Direct
Coordination
Precision
G Delay (Hz)
YawDamping(dB)
-30 -10
3.5
0
European Competitor
Fast Response
Coordination
European Competitor
Agile
Touring
LX
Previous Civic
Touring
LX
New Civic
Previous Civic
Best in class agility
New Civic
Yaw Gain (Hz)
GDelay(Hz)
0.1 0.5
-30
-10
25. Body | Platform Flexibility
Optimized body construction for platform commonality
• Increased Civic family commonality
• Increased future model commonality
2 Door / 4 Door Shared Stampings
Engine Room Strength:
Stronger front side frame can be
used for heavier future models
Variable Wheelbase:
Front floor can be easily extended for
longer wheelbase vehicles.
Variable Rear Overhang:
Rear floor can be shortened or
extended for Civic family or future
vehicles.
26. Body Structure Material Grades
PHS : 1500
UHSS : 980-1180
AHSS : 590-780
HSS : 340-440
LSS : 270
Aluminum : 6xx x Series
Fiber Reinforced Plastics
Others
58%
9
23
12
14
16M Civic has a HSS Application Ratio of 58%
(Previous 13M only applied 55% HSS)
Material Grades
Use of hotstamp increase
from 1% 14%
Efficient material use enables excellent NV,
Dynamics, and Safety Performance
28. Ride / Handling / NV Performance
16M Civic increases body TORSION by 25% allowing
for TOP IN CLASS HANDLING.
HANDLING
RIDE COMFORT
ENGINE NOISE
BOOMING
ROARD NOISE
KEY connection areas to reduce
IDLE VIBRATION & BOOMING
Floor cross members to improve
RIDE COMFORT
Addition of cross
car brace to
improve
HANDLING
Cross member structure for
HANDLING
Dash board lower stiffner to
improve HANDLING
Damper house stiffener to
reduce CRANK NOISE
Tactically placed
GUSSETS to reduce
ROADNOISE
Internal rear structural ring
to improve HANDLING
Closed Ring Rear Bulkhead
* Measurements taken without Subframe.
Static Stiffness Previous 16M
Increase
Ratio
Bending (N/mm)
Torsion (N/mm)
6750
28800
8050
35975
19%
25%
29. Weight Reduction Sources
Improved body construction and technology allows size
and stiffness increase at reduced weight
Aluminum front bumper
beam & crush cans
-2.4kg
Resin front bulkhead
-1.5kg
Adaptive Resistance Welds –
short pitch spot welding on door ring area
-1.2kg
Expansion of hot stamping
1% 14%
-7.1kg
Lightweight acoustic under
cover
-1.3kg
HSS Front Floor Panel
-2.3kg
Inner set welding construction
-2.6kg
30. Weight Reduction Sources
Hot Stamping and 980MPa materials used in B-Plr improve safety
at reduced weight
PHS Laminated Blank
PHS : 1500
UHSS : 980-1180
AHSS : 590-780
LSS : 270
Material Grades
Tailor Welded Inner
-0.18kg
Previous Civic 16M Civic
590MPa Construction
+15 spot welds
Two Piece Inner Panel
+6 spot welds
-1.59kg
Pressed with
main stamping
-20%
Weight Reduction
31. Body NVH Treatment
16M Civic achieves TOP IN CLASS NV PERFORMANCE
at all grades levels.
Leak performance
ENGINE NOISE
WIND NOISE
ROAD NOISE
BODY SEALING
Hood insulator
Dashborard
outer insulator
Engine under
cover insulation
Acoustic fender partitions
Fender enclosure
Front
fender
inner
Application of
BAFFLE PLATE with
NV MICRO PERFORATION
Dashboard insulator
Wheel house
insulators
Application of
FELT rear inner fender
Application of
FR Floor under cover
(HDPE : LX FELT: EX, TOURING)
NV Separator locations
Increased body sealing efforts to
reduce WIND, ROAD, & ENGINE
NOISE
Wind noise
Quietness
Less
Howl
More
IsolationAsia
12M Civic
14M Civic
EU
EU
MidFrequency(overalldBA)
High Frequency (overall dBA)
Less
Rimble
More
Isolation
Top Class
NVH
Top Class
NVH
SmootheSurface(overalldBA)
Rough Surface(overall dBA)
Asia
16M Civic
12M Civic
14M Civic
EU
Asia USA
ASIA
USA Touring
LX
16M Civic
34. Presentation Outline
Complete Vehicle Safety Design
Front Crash
Protection
(NCAP & ODB)
Rear Crash Protection
Side Impact Protection
(SICE)
Roof Crush Protection
Pedestrian Protection
Small Overlap
Protection
(SOT)
35. Vehicle Safety Features & Structure
Key Design features provide the highest level of crash performance,
while maintaining styling, weight, and technology targets.
• Mullti-Crush Can, High Load Front Bumper System
• High Load Capacity Sub Frame with Link Bracket
• Tailor Tempered Hotstamp Center Pillar
• Tailor Tempered Hotstamp One Piece Rear Frame
36. Vehicle Safety Features & Structure
Detail A
SOFTZONE : HT550
(TS 550~650MPa)
HOTSTAMP :
(TS 1500MPa)
SOFTZONE :
placement allows for
desired SIDE CRASH
MODE while reducing
weight compared to
previous generation Civic
(▲ 3.1kg/car)
SMALL SOFTZONE :
HT550 (TS 700~800MPa)
SMALL SOFTZONE :
HT550 (TS
700~800MPa)
SMALL SOFTZONE :
placement allows for desired
RR FRM MODE while reducing
weight compared to previous
generation Civic
(▲ 4kg/car)
HOTSTAMP
(TS 1500MPa)
PROCESS EQUIPMENT
(direct PHD process)
Blanking A
Auxiliary process
Loading Heating B
Press hardening process
StampingC Laser D
Poset operation
16M Civic utilizes Gestamp IN-DIE SOFTZONE technology to
achieve tailor tempered area within a single part.
Detail B
Detail A
Transfer parts
Cooling
Transfer parts
IN-DIE COOLLING
allows for partial tempered zones
Detail B
38. US NCAP | Concept
Maintaining the styling concept resulted in a reduction of 30mm of crash stroke.
In order to achieve this, a new crash concept was developed.
Crash Stroke
BodyG
Typical New
Styling Concept Crash Concept
1. Control G-Loading into Cabin
2. Maintain styling concept
-30 mm
-30 mm
39. US NCAP | Construction
Previous Civic 16M Civic
New High Strength Load Path
Reduced Loading
of Cabin
Increased
Strength
45. Side Crash | Concept
1. Minimize Intrusion
2. Passenger Protection
Side crash concept is to maximize loading of large high strength
cross car sections to minimize intrusion and occupant injury.
46. Side Crash | Construction
Detail A
Detail A
SOFTZONE : HT550
(TS 550~650MPa)
HOTSTAMP :
(TS 1500MPa)
SOFTZONE :
placement allows for desired SIDE
CRASH MODE while reducing weight
compared to previous generation
Civic
(▲ 3.1kg/car)
47. Side Crash | Achievement
US NCAP POLEUS NCAP MDB IIHS SICE
GOOD
50. Platform Concept | Rear Crash
Rear crash concept was developed to maximize efficiency of the rear
frame and minimize intrusion towards the fuel system.
B
C A
FrameLoad
Frame Crush
Average Load
Frame Bending Concept
51. Rear Crash | Construction
SMALL SOFTZONE :
HT550 (TS 700~800MPa)
SMALL SOFTZONE :
HT550 (TS 700~800MPa)
HOTSTAMP
(TS 1500MPa)
Detail B
Detail B
SMALL SOFTZONE :
placement allows for desired RR
FRM MODE while reducing
weight compared to previous
generation Civic
(▲ 4kg/car)
52. Rear Crash | Results
Component Test Vehicle Test
FrameLoad
Frame Crush
54. Honda Sensing™ | Advanced Safety & Driver Assist Technology
HondaSensing™
ACC with Low Speed Follow
Lane Keeping Assist System
Road Departure Mitigation
CMBS (Vehicles & Pedestrians)
Forward Collision Warning
Lane Departure Warning
™
™
Millimeter Wave Radar
+
Monocular Camera
55. Start from a Clean Sheet
All New
Chassis
All New
Body
Two All New
engines
Create an “epic civic”
How do we create the best
C–Segment vehicle in the world ?