Future Steel Vehicle—Phase 3

ETA Engineering
Case Study - FSV P3
Final Phase
Full Vehicle System 3G & 3B Optimization Applied
to Reduce Mass, Total Lifecycle Emissions &
Improve Manufacturability using AHSS
Key Achievements
1. Reduced PD Cost in Concept
& Development Phase
2. Reduce Mass By 39%
3. Reduced Total Lifecycle
Emissions by nearly 70%
4. Reduced mass and emissions
at no cost penalty
During the final phase of WorldAutoSteel’s FutureSteelVehicle Program, Engineering Technology Associates, Inc. (ETA)
was able to reduce the mass of the vehicle by 39% and reduce total lifecycle emissions by nearly 70% with no cost
Optimization of the vehicle from vehicle baseline, to detailing of the steel body structure concepts, allowed the team to
achieve aggressive mass targets of 176 kg, while meeting 2015-2020 vehicle performance objectives, as well as
total lifecycle Greenhouse Gas emissions targets. FSV’s steel portfolio, including over 20 different AHSS grades
representing materials expected to be commercially available in the 2015 – 2020 technology horizon, were utilized
during the material selection process by analyzing the full vehicle for the optimal material grades and thicknesses.
To achieve these significant results, ETA used its proprietary Accelerated Concept to Product (ACP) Process®. The ACP
Process® is a performance-driven, holistic product design development method, which is based on design optimization.
ACP incorporates the use of multiple CAE tools, including optimization tools in a systematic process to generate the
optimal design solution.
The ACP Process® included the application of multi-disciplinary 3G Optimization™ (Geometry, Grade, Gauge) to ensure
that the new design would still meet or exceed all 2015-2020 vehicle performance objectives. 3B Optimization™ (Bead,
Blank Geometry, Binder Pressure) was also applied, which allowed the team to reduce part complexity, reduce
additional mass, as well as make the parts manufacturable more quickly.
Above is a summary of the grade and gauge changes showing the parts that were updated by changing
grades and/or gauges due to reflect design optimization and formable front rail results.
Case Study - FSV P3
ETA Engineering
Final Phase
With design optimization updates incorporated, the new (T6) Baseline body structure was reduced to 176.8 kg mass.
The T6 Baseline exhibited significantly better crash performance than the T5 Final version in several of the load cases,
indicating potential additional mass saving. The following is a summary of the results.
The next step was to improve NCAP and Torsion results by balancing the gauges, particularly for the new TRIP 800
front rail sub-system, for better performance and potential additional mass reduction.
At this stage in the ACP Process®, the designed vehicle system met all vehicle performance and a 39% mass reduction,
based on vehicle class and mass targets. The following is a diagram showing the mass reduction evolution.
FSV Mass Evolution