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Chrysler, Daimler and AISI Team up to Optimize Future Vehicle Structures
08/23/2007 - AISI, Chrysler and Daimler work together on the application of advanced steel and manufacturing technologies to future vehicles, leading to the development of steel-intensive solutions and a design with enhanced fuel economy and improved structure.
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Through a cooperative effort to bring advanced steel and manufacturing technologies to future vehicles, AISI, Chrysler and Daimler have developed steel-intensive solutions to their design challenges.
Chrysler products are using increasing amounts of this new technology as demonstrated by select 2008 products, including the new Chrysler Sebring.
"Chrysler is continually developing improvements in safety and fuel economy, which are usually competing objectives," said Bill Grabowski, Director Body Core Engineering for Chrysler. "By working with AISI and our colleagues at Mercedes Group Research and MB Tech, we are able to achieve both objectives simultaneously to achieve the most efficient solution."
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The organizations took a holistic approach to sheet metal structures (body-in-white) and applied new engineering computer modeling technology ("topology") to generate efficient energy and load management, then added the latest advanced high-strength steels to achieve lighter weight objectives and improved occupant protection.
At the center of the development is a new Computer-Aided Engineering (CAE) modeling tool called topology optimization. This program identifies the body-in-white’s areas of highest strain, and then determines the optimal location for the critical load paths that would meet predetermined requirements for safety, stiffness and durability. These optimized load paths are then analyzed with respect to new advanced high-strength steel materials. The result is a superior structure that meets or exceeds future safety and performance standards. Overall vehicle weight was reduced by up to 13% compared to vehicles using conventional high-strength steels and design methods. This result is a design with both enhanced fuel economy and improved structure.
"Chrysler is continually developing improvements in safety and fuel economy, which are usually competing objectives," said Bill Grabowski, Director Body Core Engineering for Chrysler. "By working with AISI and our colleagues at Mercedes Group Research and MB Tech, we are able to achieve both objectives simultaneously to achieve the most efficient solution."
AISI, Chrysler and Daimler’s cooperative efforts to bring advanced steel and manufacturing technologies to future vehicles led them to develop steel-intensive solutions to their design challenges. Chrysler products are using increasing amounts of this new technology as demonstrated by select 2008 products, including the new Chrysler Sebring.
"We utilized spatial relationships and put the material and strength where it best serves the structure. Through this joint project, we introduced Chrysler and Daimler to new steel materials that achieve significant mass savings and satisfy tough vehicle requirements," said Ron Krupitzer, Vice President of the American Iron and Steel Institute's Automotive Applications Committee.
The project team includes engineers from Chrysler, Mercedes Group Research, and Mercedes Benz Technologies (MB Tech) who employed the latest computer-aided design (Catia V5) and computer-aided engineering (CAE) - topology tool to improve vehicle development.
AISI serves as the voice of the North American steel industry in the public policy arena, advances the case for steel in the marketplace as the preferred material of choice, and plays a lead role in the development and application of new steels and steelmaking technology. AISI is comprised of 32 member companies, including integrated and electric furnace steelmakers, and 125 associate and affiliate members who are suppliers to or customers of the steel industry.
The Automotive Applications Committee (AAC), a subcommittee of AISI’s Market Development Committee of AISI, focuses on advancing the use of steel in the highly competitive automotive market. With offices and staff located in Detroit, cooperation between the automobile and steel industries has been key to its success. This industry cooperation resulted in the formation of the Auto/Steel Partnership, a consortium of Chrysler LLC, Ford Motor Co., and General Motors Corp., and the member companies of the AAC.
Headquartered in Auburn Hills, Mich., Chrysler LLC produces Chrysler, Jeep(R), Dodge and Mopar(R) brand vehicles and products. Total sales worldwide in 2006 were 2.7 million vehicles. Sales outside of North America were the highest in a decade with an increase of 15% over 2005. On the heels of the company's record product launch year (Chrysler launched 10 all-new vehicles in 2006), the company plans to extend that streak with eight all-new products in 2007. Its product lineup features some of the world's most recognizable vehicles, including the Chrysler 300, Jeep Commander and Dodge Charger. The Chrysler Foundation, the company's philanthropic arm, gave $23.6 million in grants in 2006.
