door inner mass optimization using curvilinear laser …/media/files/autosteel/great...

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w w w . a u t o s t e e l . o r g Door inner mass optimization using curvilinear laser welding Kalyan Palanisamy Shiloh Industries

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Page 1: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Door inner mass optimization using curvilinear laser

welding

Kalyan Palanisamy

Shiloh Industries

Page 2: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Agenda

What is Curvilinear Laser welding

Door Inner Case study

Linear Vs Curvilinear options

Different material grades

Formability advantages

Stamped Door Inner

Structural Analysis

Cost and Quality Advantages

Summary

Page 3: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Why use Laser Welded Blanks

Different gauges, materials & coatings can be incorporated into one

blank

Component can be engineered to desired properties

Improved energy management

Consolidation of components

Reduction in number of parts

Reduced tooling costs

Reduced assembly operations and equipment

Reduction in variation due to assembly tolerances

Material utilization

Reduction in engineered scrap due to improved blank nesting

Mass reduction on vehicle

Page 4: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Types of Welded Blanks

Thin

gauge

Thick

gauge

Multi - Linear

Thin

gauge

Thick

gauge

Curvilinear Linear Curvilinear

Thin

gauge

Thick

gauge

Thin

gauge

Thick

gauge

Page 5: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Curvilinear Laser Welded Blanks

Page 6: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Door Inner Case Study

Optimization of Current Monolithic Door Inner

Platform Priority

Optimize cost

Optimize weight

UPR HNG BRKT

Check Load BRKT

LWR HNG BRKT

FRT DR INR

Gauge : 2.50 mm

Mass Usage : 0.45 kg.

Gauge : 2.50 mm

Mass Usage : 0.42 kg.

Gauge : 1.50 mm

Mass Usage : 0.21 kg.

Gauge : 0.80 mm

Mass Usage : 5.66 kg.

Baseline on vehicle mass Usage = 6.74 kg

Baseline gross steel usage = 12.84 kg

Page 7: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Linear Laser Welded Option

Linear Laser Welding Design

1.40 mm

0.80 mm

Monolithic Design

Monolithic Design Option 1

Part Gauge

In mm

Material

Usage

in kg

Mass

in kg

Gauge

In mm

Material

Usage

in kg

Mass

in kg

FDI 0.80 10.8 5.66 1.40 5.14 2.73

UPR HNG

BRKT

2.50 0.98 0.45 0.80 8.07 4.11

MDL BRKT 1.50 0.33 0.21 - - -

LWR HNG

BRKT

2.50 0.73 0.42 - - -

Total 12.84 6.74 - 13.21 6.84

Savings in kg - - (0.37) (0.10)

• Mass increase of 0.10 kg on vehicle

compared to monolithic

• Material increase of 0.37 kg

• Not a good solution

Page 8: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Curvilinear Laser Welded Option

Option 1 – Curvilinear Laser Welding

Monolithic Design Option 2

Part Gauge

In mm

Material

Usage

in kg

Mass

in kg

Gauge

In mm

Material

Usage

in kg

Mass

in kg

FDI 0.80 10.8 5.66 1.40 3.17 2.0

UPR HNG BRKT 2.50 0.98 0.45 0.80 9.32 4.56

MDL BRKT 1.50 0.33 0.21 - - -

LWR HNG BRKT 2.50 0.73 0.42 - - -

Total 12.84 6.74 - 12.49 6.56

Savings in kg - - 0.35 0.18

• Material savings of 0.35 kg

• Vehicle Mass savings of 0.18 kg

• Total Value Chain Cost Decrease

1.40 mm

0.80 mm

Monolithic Design

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Curvilinear Laser Welded Option

Option 2 – Curvilinear Laser Welding

Monolithic Design Option 2

Part Gauge

In mm

Material

Usage

in kg

Mass

in kg

Gauge

In mm

Material

Usage

in kg

Mass

in kg

FDI 0.80 10.8 5.66 1.20 2.72 1.70

UPR HNG BRKT 2.50 0.98 0.45 0.80 9.32 4.56

MDL BRKT 1.50 0.33 0.21 - - -

LWR HNG BRKT 2.50 0.73 0.42 - - -

Total 12.84 6.74 - 12.04 6.26

Savings in kg - - 0.80 0.48

• Material savings of 0.80 kg

• Vehicle Mass savings of 0.48 kg

• Total Value Chain Cost Decrease

BH

1.20 mm

0.80 mm

Monolithic Design

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Formability with Different Material Grades

270 BH

1.2/0.8 mm

Thinning near weld line:

Max. (20.3%)

1.4/0.8 mm

Thinning near weld line:

Max. (18.7%)

180 BH

1.4/0.8 mm

Thinning near weld line:

Max (18.4%)

CR4 Thick Gauge

Material

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Formability Advantage B

lan

k

Fin

al

Form

T

hin

nin

g

Thinning Near Weld: 39.3% 33.6% 16.3% 16.6%

Original Straight Line

Formability Issues Solution#1: Straight Solution#2: Curvilinear

Mass Savings: 0.47kg

(from Solution #1)

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Formability with Different Material Grades

270 BH 180 BH CR4

0.8 mm 0.75 mm 0.75 mm 1.40 mm

1.40 mm 1.20 mm

CR4 180 BH 270 BH

Mass on vehicle 8.15 kg 7.43 kg 7.17 kg

Mass savings 0.00 0.72 kg 0.98 kg

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Stamped Door Inner

1.2 mm 270 BH

Page 14: Door inner mass optimization using curvilinear laser …/media/Files/Autosteel/Great Designs...Kalyan Palanisamy Shiloh Industries w w w . a u t o s t e e l . o r g Agenda What is

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Structural Analysis

Curvilinear Laser Welded Blank Option

Monolithic Curvilinear Option

1

Curvilinear Option

2

Check load strain Baseline

Vertical rigidity - Deflection Baseline

Vertical rigidity - Set Baseline

Upper frame stiffness Baseline

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Cost & Quality Advantages

• Eliminate 23 spot welds and processing time

• Eliminate 3 stamped parts and its stamping dies

• Eliminate Assembly equipment & labor

• Eliminate floor space required for 3 stamped parts

• Eliminate transportation & inventory of stamped parts

• Better dimensional control for door assembly

• Heavier gauge covers more area than the localized brackets

improving stiffness

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Optimized Door Inner Cost Estimates

Baseline Design Curvilinear EWB Design

Manufacturing Operations

Blanking

Laser Welding

Stamping 1

Stamping 2

Stamping 3

Freight/Packaging/Inventory

Assembly/Spot Welding

@ 5.2 % lower Costs

0.48 kg Mass Reduction

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Summary

• Curvilinear laser welding enables optimize door inner

• Mass savings

• Material savings

• Consolidation of hinge brackets

• Improves dimensional control

• Improves fit and finish

• Reduction in secondary processing (stamping/welding)

• Cost savings

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Kalyan Palanisamy [email protected]

Phone: 248.229.9024

Thank you

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