A Winner: Car Body Design Development

of the Hyundai Sonata

Carsten Hfer

Hyundai Motor Europe Technical Center

www.autosteel.org

Product Concept /

Product Concept

Background
Background
History
History proposition
Customer
Customer proposition
Styling
Styling
Practicality
Practicality
Performance
Efficiency
Efficiency

Development process
Development
Platform
strategyprocess
Weight
optimization
Weight
optimization
Stiffness
Stiffness
Material
Material
Safety
Safety

Overview of Ulsan Plant

Manufacturing strategy
Flexible production system
Productivity
Quality

BiW Concept

Hyundai Sonata at GDIS Conference 2013

BIW Concept

i40 intro.m4v

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept

Product Concept /

2010 Sedan

BIW Concept

2011 Sedan & Wagon

2004
1998
7
Hyundai Sonata at GDIS Conference 2013

Product Concept

Product Concept /

BIW Concept

Best in class roominess

Class leading practicality

Best in class with 113g CO2/km

3 USPs: rear seat reclining, auto

defog, heated steering wheel

Sporty and emotional

Modern interior

Target best in TCO

Competitive pricing

Hyundai Sonata at GDIS Conference 2013

Product Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept

Product Concept /

BIW Concept

Cargo capacity 19. 5 cu. ft. (553 liters) with the rear seats occupied
Up to 60.7 cu. ft. (1718 liters) with the rear seats folded down

Hyundai Sonata at GDIS Conference 2013

Product Concept

Product Concept /

BIW Concept

10,082

8,840

22%
8,013

214
0.32

0.30
0.29

148
0.29

Cd
Predecessor i40

Hyundai Sonata at GDIS Conference 2013

Competition

CO2
(g/km)

8,878

155

132

Predecessor i40

Competition

Predecessor

i40

Competition

Product Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

BIW Concept

Product Concept /

BIW Concept

Full schedule predecessor 24M

Model
Fix

Design

Test

-2

Model
Fix

Design

SOP

-4

Test

-6

SOP
Full schedule i40 18M

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

Achieved a 7.6% reduction in BIW weight compared to predecessor.

456.3kg

EVI process
-27.3kg

Design optimization

438kg
438kg

Design concept

Hyundai Sonata at GDIS Conference 2013

Final drawings

Competition

BIW Concept

Product Concept /

BIW Concept

Rearranging the part assembly allowed for a reduction of the material thickness
From single part with uniform thickness to three parts with different, optimized
thickness

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

Change of the form from linear interior to radial interior lead to a material
thickness reduction
Divergence angle to improve airflow and NVH performance

Spare Member (1.0 )

Hyundai Sonata at GDIS Conference 2013

Spare Member (0.8 )

BIW Concept

Product Concept /

BIW Concept

Increased the torsional stiffness by 141% and the bending stiffness by 19%.
Achieved 11% more torsional and 23% more bending stiffness compared to competition

28.6

35.3

24
0.32

14.6

Predecessor

Hyundai Sonata at GDIS Conference 2013

0.29

i40

BIW Concept

Product Concept /

BIW Concept

Continuous members from engine room to rear floor in longitudinal direction

Connections of floor, sides and roof form closed circular structures
Main joints optimized by extensions and closed profiles

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

The formation of a closed section connecting the underbody, cowl area

and suspension strut improves the stiffness of the front-area
This also increases the local stiffness of the suspension strut dome resulting in
improved driving performance

+87%

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

The vehicle rear end is reinforced by a double structure ring shape section
The ring shapes are interconnected in longitudinal direction by the rear side
members, waistline profiles and roof rails

+67%

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

The roof stiffness is increased by local extensions

Optimized energy flow through maximized overlap
Increased local stiffness through constant section profile

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

Application of 71m of structural adhesives leads to body stiffness increase of 14%

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

3.1 3.6
35.6

6.1

28.5
23.2
MS (120 280 MPa)
HSS (180 640 MPa)
AHSS (220 720 MPa)
UHSS (620 1280 MPa)
PHS (980 -1260 MPa)
Fibre reinforced plastic
Hyundai Sonata
i40 at Euro
Car Body
Conference
Hyundai
at GDIS
Conference
2013 2011

BIW Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

BIW Concept

Product Concept /

BIW Concept

EuroNCAP comments:
Driver knee airbag is standard equipment
Maximum score for side barrier impact
Bumper area scored maximum points for pedestrian protection
Speed limitation assistance is standard equipment for best selling variant

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

24%
11%
100%
12%
89%
64%

4%
20%
12%
4%
20%
80%

14%
36%
30%

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

BIW Concept

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

1.3%

BIW Concept

13.2%

16.3%
11.2%
12.0%

12.3%

21.1%

12.6%

Hyundai Sonata at GDIS Conference 2013

BIW Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

BIW Concept

Product Concept /

Hyundai Sonata at GDIS Conference 2013

BIW Concept

BIW Concept

Product Concept

World Car Concept

Focused on local market customer demands
Supporting Hyundais philosophy of Modern Premium
Featuring Hyundais design language of Fluidic Sculpture

BiW Concept

Streamlined development process of 18 months

CAE driven design for best performance and lowest cost
Highly efficient use of High Strength Steels
Excellent Light Weight Index to meet ecological demands
Safe for Occupants and Pedestrians

Hyundai
Hyundai Sonata
Sonata at
at GDIS
GDIS Conference
Conference 2013
2013

Product Concept

North American
Light Vehicle Metallic Material Trends

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