Automotive weight reduction through nonlinear finite element modeling, fatigue analysis, and optimization of hot stamped ultra-high strength steels

点击翻译按钮获取中文摘要

Automotive transportation is the dominant form of transportation in the industrialized world. There are an estimated 1.3 people for every vehicle on the road today in the United States alone; 1.6 people for every vehicle on the road in Canada. As expected with such a large industry, there is a competitive market for each supplier and manufacturer. Lower cost, higher performance, and environmentally conscious products are of predominant concern for companies competing today. Magna Powertrain, a major tier-1 supplier in the automotive industry, is developing an alternative clutch hub to their existing performance system. In order to remain competitive in the marketplace as greenhouse gas emission standards continue to increase, Magna Powertrain is targeting a new design that employs ultra-high strength boron steel. The successful implementation of the material into a new clutch system would represent significant weight savings, translating directly into improved fuel efficiency. Currently boron steel is employed largely in crash structures in the automotive market with little expansion into other applicable vehicle areas in which car makers have limited experience. Using the current Magna Powertrain clutch hub design as a benchmark, research will be expanded to the use of martensitic boron steel for the next generation's replacement. Novel high cyclic fatigue research will be conducted using single and multiphase fraction boron steel, addressing the current research void. Numerical modelling and design optimization of the clutch component will serve as a means to develop fatigue considerations in multiphase high cyclic structural components. Metrics including component mass and fatigue strength will be of particular focus for this study. Manufacturing optimization will simultaneously be considered in an effort to realize a more effective design. A target of 30% weight reduction in the component has been set, which would correspond to a decreased fuel consumption of 7 liters over the life of the product, per vehicle implementation. One Master's student will be trained, including on-site internship at Magna.****