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

汽车运输是工业化世界的主要交通方式。据估计，仅在美国，目前每辆汽车对应1.3个人；在加拿大，每1.6个人对应一辆车。正如预期的那样，在如此庞大的行业中，每个供应商和制造商都有一个竞争激烈的市场。低成本、高性能和环保意识的产品是当今公司竞争的主要关注点。汽车行业的主要一级供应商麦格纳动力系统公司正在开发一种替代离合器轮毂的现有性能系统。随着温室气体排放标准的不断提高，为了在市场上保持竞争力，麦格纳动力总成正在瞄准采用超高强度硼钢的新设计。如果将这种材料成功应用到新的离合器系统中，将显著减轻重量，直接转化为燃油效率的提高。目前，硼钢主要用于汽车市场的碰撞结构，很少扩展到汽车制造商经验有限的其他适用汽车领域。以目前的麦格纳动力总成离合器轮毂设计为基准，研究将扩展到使用马氏体硼钢替代下一代。利用单相和多相分数硼钢进行新型高周疲劳研究，弥补了目前研究的空白。离合器部件的数值模拟和设计优化将作为开发多相高循环结构部件疲劳考虑的手段。包括部件质量和疲劳强度在内的指标将是本研究的重点。为了实现更有效的设计，将同时考虑制造优化。该组件的减重目标已设定为30%，这相当于在产品的整个生命周期内每辆车的油耗减少7升。一名硕士生将接受培训，包括在Magna.****的现场实习

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.****