Advanced High-Strength Steel Technologies in the 2014 Chevy ...

2014 Chevrolet Silverado/GMC Sierra Body 1500Cab Structure ReviewThomas GrabowskiGeneral MotorsCompanyw w w . a u t o s t e e l . o r g

Vehicle Introduction–Chevrolet SilveradoSilverado’s exterior design blendsstrong Chevy truck heritage with arefined, modern aesthetic…w w w . a u t o s t e e l . o r gHauling goods since 1918…

Vehicle Introduction – GMC SierraGMC designers approached the exterior with respectfor its predecessors, evolving its familiar shape whileadding distinctive details…A century of truck production…w w w . a u t o s t e e l . o r g

High-level Changes From Current Truckw w w . a u t o s t e e l . o r g

High-level Changes From Current Truck• Improved Noise and Vibration performance• New inset door design – Triple seal system, reduced wind noise2013 rear door opening2014 rear door openingw w w . a u t o s t e e l . o r g

High-level Changes From Current Truckw w w . a u t o s t e e l . o r g

Anticipated Segment Firsts• Direct Injection, ActiveFuel Management, andVariable Valve Timingpowertrains are standardacross the lineup• The first Direct Injected V-8 in a light duty pickupw w w . a u t o s t e e l . o r g5.3L V-8 EcoTec3 AFM VVT DI

Anticipated Segment Firsts• Standard projector headlamps onGMC Sierra• Standard DuraLife brake rotors• Forward Collision Alert /LaneDeparture Warning /Safety Alert Seat• Real aluminum interior trim• Ultrasonic front park assistw w w . a u t o s t e e l . o r g

All New Cargo Box Innovations• CornerStep rear bumper• Moveable cargo box upper tie-downs• LED under-rail box lightingw w w . a u t o s t e e l . o r g

Three Available Cab ConfigurationsRegular Cab• 8’ box shown• 6’6” availableDouble Cab• 6’6” box shownCrew Cab• 5’8” box shown• 6’6” availablew w w . a u t o s t e e l . o r g

Redesigned Interior: Silverado Shownw w w . a u t o s t e e l . o r g

All New 8” Color Touch Screen OptionRedesigned interior:hand stitchedpanels, touchscreenw w w . a u t o s t e e l . o r g

Redesigned Seating: Sierra Shownw w w . a u t o s t e e l . o r g

Interior Functionality: Silverado Shownw w w . a u t o s t e e l . o r g

Cab Structure Development: Introductionw w w . a u t o s t e e l . o r g

Cab Structure Development: Agenda1. Body in White Objectives2. Vehicle durability3. Material selection4. Part commonality5. Safety structure6. Mass reduction strategies7. Noise/Vibrationmanagementw w w . a u t o s t e e l . o r g

Objectives of the Body in White Design• Performance goals of the BIW:– Outstanding performance on allgovernmental and consumer safetymetrics.– Enhanced overall stiffness for handlingand Noise/Vibration performance.– Mass Reduction without compromisingDurability.• Manufacturing goal– Drive part commonalityto enable productionin three assembly plants.w w w . a u t o s t e e l . o r g

Vehicle Durability Videow w w . a u t o s t e e l . o r g

Vehicle Durability Videow w w . a u t o s t e e l . o r g

Material Selection – Upper StructuresMild SteelBake HardenableHSLADual-Phase/Multi-PhasePress Hardened Steelw w w . a u t o s t e e l . o r g

Material Selection – Lower StructuresMild SteelBake HardenableHSLADual-Phase/Multi-Phasew w w . a u t o s t e e l . o r g

Material Selection –Extensive Use Of Press Hardened SteelMild SteelBake HardenableHSLADual-Phase/Multi-PhasePress Hardened SteelMaterial Breakdown by partcount6%28%24%23%19%w w w . a u t o s t e e l . o r g

Manufacturing Footprint2012 Silverado andSierra total salesvolume: 575,497Flint Asm, Michigan• Crew Cab• Regular CabFort Wayne Asm, Indiana• Double Cab• Regular CabSilao Asm, Mexico• Crew Cab• Regular Cabw w w . a u t o s t e e l . o r g

Part Commonality Across Three Cab ConfigurationsCommon on all Cab’sCommon Double and Crew CabUnique to Crew Cab• Common doorhardwaresystem• Flexibleassemblytooling• Reducesinvestment,piece cost24%25%51%Crew Cab commonalitybreakdown by part countw w w . a u t o s t e e l . o r g

Part Commonality Across Three Cab Configurations• Common PressHardened Steeldie tooling• Dual cavitytooling reducesinvestment• Higher volumesdecrease piececostDual cavity toolw w w . a u t o s t e e l . o r g

Reinforcement Safety CageU.S. Roof strength:– IIHS– Two Sided (FMVSS 216A)Load VectorLoads are carried by:• Front roof header• #2 Roof bow• PHS roof rail outer• Center pillar assemblywith shear platew w w . a u t o s t e e l . o r g

Reinforcement Safety CageSide Impact:– IIHS– Side NCAP– FMVSS 214Side impact loads aredissipated through:• PHS center pillar assembly• Rocker outer assembly• PHS roof rail assembly• #2 PHS roof bowLoad Vectorw w w . a u t o s t e e l . o r g

Safety Cage – Key ReinforcementsArc brazedshear plateDual Phasewelded tubereinforcementPress HardenedSteel pillarreinforcementDual Phase rockerreinforcementw w w . a u t o s t e e l . o r g

Reinforcement Safety Cage – Center Pillar Asm• Consistent geometry in loadpath, initiator free• Shear plate offsets smallercross section• Arc brazing reduces B&Rweld flange stack-upArc brazed LowAlloy shear platePress HardenedSteel pillarreinforcement asmw w w . a u t o s t e e l . o r g

Reinforcement Safety Cage – Rocker AsmHigh-FrequencyInduction weld joint• High-frequency inductionwelding, enables a designspecific tube reinforcement• Resistance welded to rockerreinforcementDual Phasewelded tubereinforcementResistance weld jointw w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Roll Forming• Roll formedplatform forlower mass andhigher cargocapability• Minimizesthinning forincreaseddurability• Roll formedcross sillsPickup Boxw w w . a u t o s t e e l . o r gHSLA0.95mmHSLA1.2mm

Mass Reduction Strategies – Tailor Welded Blank• Gage reductionoutside of load path• Enables currentassembly process• Joint avoidance inload sensitive areaDualPhase1.2mmDualPhase0.8mmw w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Tailor Welded BlankMild Steel0.75mmR100Bake Hardenable1.6mmDoor innerRear door Blankw w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Part ConsolidationDual PhasereinforcementDesign for Six Sigma projectenabled an integrated sunvisor attachment related toFMVSS 201 executionMild steel mountingplate reinforcementReference DesignDual PhasereinforcementOptimized Designw w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Part Boundary ReductionMaterialupgradeenabledReference DesignOptimized Designw w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Scallop Flange UtilizationGeneral MotorsGlobal Best Practicew w w . a u t o s t e e l . o r g

Mass Reduction Strategies – Torsional Optimization• Welded corner bracketprovided a 4% increasein torsion performance• Enable the removal of aless efficientreinforcement.• Created down gagingopportunity's onsurrounding panelsView inside cabw w w . a u t o s t e e l . o r g

Noise/Vibration Management – Body Mount Development• Change to shearstylebody mountinsulator• 50% increase inlocal structurestiffness requiredw w w . a u t o s t e e l . o r g

Noise & Vibration Management – Sealing StrategyBody sealerStructural adhesive• Optimized bodyjoints to enablerobust sealing• 103% increasein structuraladhesive• 44% reductionin airbornenoise paths.w w w . a u t o s t e e l . o r g

Noise & Vibration Management – Shape OptimizationDesign for Six Sigmamethodology appliedto developed beadshapes resulting inreduced back panelvibration.w w w . a u t o s t e e l . o r g

Noise/Vibration Management – Body Stiffness• 17% increase inGlobal Torsionalperformance• 10% increase inGlobal BendingTorsionalModeBendingModeTorsionalModew w w . a u t o s t e e l . o r g

Summary• Ultra High Strength Steel stampings enabled a significantincrease in safety performance with mass efficiency• Part commonization strategy reduced tooling investment• Optimized part geometry enables mass efficiency• The 2014 Silverado/Sierra weighs 110 lb less on averagethan its major competitorw w w . a u t o s t e e l . o r g

THANK YOUThomas GrabowskiDesign Release EngineerGeneral Motors Companyw w w . a u t o s t e e l . o r g

PRESENTATIONS WILL BE AVAILABLE MAY 3Use yourweb-enableddevice to downloadthe presentationsfrom today’s eventGreat Designs in Steel is Sponsored by:w w w . a u t o s t e e l . o r g