Advanced High Strength Steel Technology in the 2006 Honda Civic Creating Special Appeal with Steel Mark Pafumi Honda R&D Americas, Inc.
I. Introduction II. Special Appeal III. DQR IV. Safety
I. Introduction II. Special Appeal III. DQR IV. Safety
New Civic Grand Concept Advance Personal Compact Balance
Providing a Unique Civic Special Appeal Feel and Impression Innovative Package Design DQR and Safety Environment Advanced Performance
Exterior Design Concept ADVANCED EMOTIONAL DESIGN SPORTY ONE MOTION FORM FORWARD CABIN SOLID & Hi-TENSION BODY
Exterior Design
ADVANCED PERSONAL COMPACT Wedged Silhouette One motion nose to cabin side Aggressive & Solid Fist like strength Trapezoid Lower Body
Coupe vs. Sedan Packaging Differences Coupe is clearly distinguished from the Sedan Sporty & Sharp Windshield -2 o MORE SPORTY STANCE! MORE EMOTIONAL STYLE! Hip Point -20 mm Wheelbase -50mm - 50mm
I. Introduction II. Special Appeal III. DQR IV. Safety
White Body Overview Target: Increase overall dimensions and add features New Features Side Air Bag 05M Civic Side Curtain Air bag 16 wheels 1.8L (larger) Engine 5-Speed Automatic Telescoping Steering White body weight = +4% Weight Summary ACE TM (Front) Body Structure Side Impact Improvements Body Structure +16 kg Rigidity (for handling) Features + 46 kg
High Strength Steel Utilization Target: Improve performance and control weight through HSS 05M Civic 11% 19% 68% 2% Grade 590 440 340 270 50% 38% 9% 3% Grade 590 440 340 270 590 MPa steel use tripled HSS Usage Rate: 32% HSS Usage Rate: 50% 50% of body now high strength steel
Front Styling Target: Realize One-motion and Crouching form styling Windshield Angle -18% Glass area +25% Length of Front End @ Center line -16% Coupe 21.9 o 05M Coupe = 26.7 o [NSX = 23.9 o ] Sedan W/S angle -18% 23.9 o 05M Sedan = 29.1 o 881 mm 05M Civic 1045 mm
Dashboard Upper Construction Target: Apply aggressive front styling and improve structural rigidityr Move base of windshield out 260 mm 05M Civic Damper house connection to DA/BD UPR less rigid 05M Civic Engine Rigid Connection DA/BD UPR Lid Apply DA/BD UPR lid Extends over engine DA/BD UPR extends over engine Lid removable for service Wiper box ties damper house together
Side Sill Design Target: Economically improve styling and acoustics of side sill 05M Civic Slope-type Side Sill Plastic Garnish Acura TSX Edge-type Side Sill Conventional PVC + Clean appearance + Good acoustics (chipping noise) -- High cost Under-cut formed by cam PVC-free acoustic (expandable) coating - Visible weld flange - Low impact damping (chipping noise) ++ Low cost + Same appearance as plastic garnish + All steel design no assembly parts + Good chipping noise + Low cost
Lower body accents Target: Economically apply model-exclusive exclusive lower body accents Coupe Sedan Theme: Simulated body side cladding Cladding molded in front & rear bumpers Theme: Strong lower character line that doubles as door protector Body side molding molded in bumper Character line creates shadow giving appearance of a body kit Side panel flared at RR wheel to provide air foil effect Unique look with zero cost! Front and rear doors apply clip-on plastic molding Front fender and side panel stamp shape of protector Unique look achieved with only two clip on garnishes
Rolled Rear Wheel Arch Target: Guarantee compatibility of wide track and tire clearance Rear wheel arch rolled after welding Allows tires to be pushed outward as far as possible Side Panel Outer RR Inner Panel After bending A Dust sealer Bend angle: 65 A SECTION AA Bending range
I. Introduction II. Special Appeal III. DQR IV. Safety
Front Subframe Target: Develop two subframes with different design constraints Efficient section Straight pipe 1.8L Engine 2.0L Engine ( (Si ) Specifications 1.8L 2.0L Material 440 MPa 270 MPa Process Hydro Stamped Thickness 2.0t 2.0t Weight 20.4 kg 22.4 kg Production location JP, US Thailand World-wide volume 450,000 50,000 Optimized design low piece price Expensive tooling but high volume AHSS allows same bending moment Bending Moment of Inertia (XY coodinates) Ix-x 69472 Economical tooling Conventional design One worldwide source 17mm M=(31*57213)/17 20mm (Yield Strength 31kg/mm 2 ) =126685 [kgmm] (Yield Strength 21kg/mm 2 ) Bending Moment of Inertia (XY coodinates) Ix-x 121548 M=(21*121548)/20 =127625 [kgmm]
Rear Crossmember Target: Improve body mounting strength for sporty suspension Reinforced for improved suspension mounting point rigidity Extra toughness for aftermarket modifications Must keep common layout to base model UPR Arm BRKT RR Crossmember EXTN RR Crossmember RR Stabilizer Mount Brkt Extend UPR Arm BRKT Countermeasures Modify RR Crossmember bulkhead Exclusive application for Si Coupe Increase thickness RR Stabilizer Mount Add SWs 2.3t 3.2t RR Crossmember - 1.2t/270 MPa Extend Internal Bulkhead Spot weld life increased 8x
Body Rigidity Target: Improve body rigidity with focus on connection details Add DA/BD UPR Gusset Result Add RR Tray to RR Inner Gusset 1.2t/590 MPa 0.8t 1.8t 590 MPa Increase thickness of Center Tunnel Frame Mode vs. 05M Civic Torsion Increase section of Side Frame to UPR Member connection 1.2t Add 2-piece FR Seat Cross Member Bending + 7.6% Torsion + 11% B-PLR LWR Add Side Sill EXTN
Rear Parcel Tray Construction Target: Control vibration input from 360W subwoofer Improves rattle/squeak toughness Prevents center seat belt retractor chatter Add beads Rear Tray mode with glass 0.6t/270 MPa Maximize speaker hole diameter Sect AA Section AA Add strap (0.6t) Final Base C/M #1 Add support (1.6t) Box section 0.6t/270 MPa 0.6t/270 MPa 5 mm Add bent flange around speaker & seat belt holes Compliance (m/n db) Subwoofer Operating Frequency (40-160 Hz)
I. Introduction II. Special Appeal III. DQR IV. Safety
Safety Target: Create high-energy absorbing structure with HSS Front Rear Side Side All critical frame members use 590 MPa steel
ACE TM Body Structure Target: Adopt advanced Compatibility Body Structure 05M Civic Load Distributing Body Frame Extended upper member joined to the side frame Load carried deep in to structure Cross section of upper member joint enlarged
Offset impact of Civic v. Pilot 05M Civic
Floor Frame Construction Target: Efficient transfer of frontal crash loads 1.6t/590 MPa 05M Civic Floor frame stops 64 KPH Offset Barrier 1.6t/590 MPa 1.0t/590 MPa Photo courtesy IIHS Load transfer to side sill Floor frame extends to side sill
Tailor Welded Blanks Target: Apply tailor welded blanks to balance performance & weight Dashboard Lower Front Side Frame Door Inner Panel Center Pillar Stiffener (4D) Front Side Frame 590 MPa Dashboard Lower 1.6t 0.8t/270 MPa Polygon shape 1.2t Apply beads to increase rigidity of section 1.4t 1.2t/590 MPa 05M Civic
Side Impact Test Modes Target: Achieve high performance in both NCAP & IIHS modes NHTSA Side NCAP Passenger Car Mode IIHS SICE Light Truck Mode Higher Weight Higher Height 11 in WT: 3015 lbs 15 in (+4 in) WT: 3300 lbs (+285 lbs) Rib G Lower Spine G Head G Two Body Regions rated to calculate Thoracic Trauma Index (TTI) TTI = Rib maxg + Lwr Spine G 2 Head Injury Criteria Neck Force/Moments Rib Deflections Four Body Regions rated Pelvis G Pelvic Forces Barrier strikes low engages side sill and B-PLR Two body regions rated No rating for structure or head protection Driver Barrier misses side sill all load carried by door & B-PLR Four body regions rated Head protection & body performance rated IIHS GOOD
Side Impact Protection ARCH A, ROOF 270MPa, t0.7 Target: IIHS Good with reduced weight and cost 05M Civic GUSSET,MID FLR C/MBR HSS MPa, t3.0 ARCH A, ROOF HSS MPa, t0.7 STIFF,CTR PLR UP HSS MPa, t2.0 GST, ROOF ARCH HSS MPa, t1.6 RNFCT,CTR PLR UP HSS MPa, t1.0 RNFCT,GUSSET HSS MPa, t2.0 PNL,RR INSIDE 270MPa, t0.65 GUSSET,MID FLR C/MBR HSS MPa, t2.6 RNFCT,MID FLR C/MBR HSS MPa, t1.6 STIFF,CTR PLR 270MPa, t2.0 PNL,RR INSIDE 270MPa, t1.2 C/MBR,MID FLR STIFF HSS MPa, t1.6 RNFCT,CTR PLR LWR 270MPa, t1.6 RNFCT B, CTR PLR LWR HSS MPa, t1.6 RNFCT, MID FLR C/MBR HSS MPa, t 2.0 STIFF,CTR PLR LWR 53% HSS (by weight) 89% HSS (by weight) HSS MPa, t1.0 Weight = -3.9 kg; Cost = -10%
Rear Impact (RR301) Target: Efficient energy absorption of rear frame Phase in RR301 regulation (80 kph RR impact) No damage to fuel tank Protect fuel filler pipe from leak Fuel System Fuel filler pipe Fuel tank Rear Frame 05M Civic Bent Frame Construction FR RR Frame 2.0t/590 MPa RR Frame Patch 0.6t/270 MPa Straight RR Floor Cross Mbr Extn 1.8t/270 MPa RR Frame Stiffener 2.3t/590 MPa RR Upper Arm Brkt 1.8t/270 MPa
Pedestrian Impact Target: Reduce head injury by applying: Energy absorbing structure Sufficient clearance to underhood components Hood Hinge Verically collapsable structure Still must meet durability & frontal crash requirements (no windshield contact) Initiator Holes Hood Meets EU/J regulation: 66% of area <1000 HIC 100% of area <2000 HIC Fender Bracket Collapsable fender mounting Clearance to UPR MEMBER Wiper Pivot (Aluminum) Break-away Structure
Safety Summary Test Mode Front NCAP Driver Driver Pass Pass Published Data Side NCAP Front Rear Offset Side Impact Neck Injury Reduction GOLD (06M) GOOD GOOD GOOD
DQR Conclusion Flexible front subframe design Rigid rear parcel tray Durable rear crossmember Enhanced body rigidity Special Appeal Lightweight white body 50% high strength steel Aggressive front styling Unique DA/BD UPR construction Integrated side sill design Stylish lower body accents Safety ACE TM body structure Energy distributing floor frame Extensive use of tailored blanks Efficient side impact structure Industry-leading pedestrian impact protection Rolled wheelarch flange All made possible with innovative use of steel