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alfa_romeo EuroCarBody benchmarking data.pdf

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ALFA_ROMEO EUROCARBODY BENCHMARKING DATA
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1 EuroCarBody 2010 12th International Car Body Benchmark Conference Car body benchmarking data summary Alfa Romeo Giulietta 1. Weights Total weight body-in-white: 372.3 kg Defined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint. Corresponding view: (The colour scheme of the parts shown makes use of the RGB colour code for the material classification, see section 2.) Additional view: EuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 2 Extra parts: Weights of separate subframes, front end modules, etc. Part description Corresponding view Weight Front bumper beam: 4.3 kg Rear bumper beam: 3.2 kg Lower load path: 4.7 kg Body-in-white weights of doors, closures and fenders Front doors (both): 35.2 kg Rear doors (both): 25.3 kg Hood: 14.4 kg Liftgate/deck lid: 11.3 kg Front fenders (both): 6.1 kg Front end modules: 12.1 kg Total weight body-in-white without doors, closures and fenders: 280 kg EuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 3 2. Material mix in the body-in-white including doors and closures Based on metallurgical/chemical material classes Materials: corresponding metallurgical classes RGB colour code % Steels Low Strength Steels: Mild steels R 153, G 204, B 255 27.9 High Strength Steels (HSS): High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA) R 051, G 102, B 255 42 Advanced High Strength Steels (AHSS): Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP) R 255, G 153, B 204 16.5 Stainless steels: Austenitic stainless steels R 051, G 051, B 153 Ultra High Strength Steels (UHSS): Complex Phase Steels (CP), Martensitic Steels (MS) R 204, G 153, B 255 Press Hardened Steels (PHS) R 128, G 000, B 128 11 Aluminium Aluminium sheets: 7xxx series R 051, G 204, B 153 Aluminium sheets: 6xxx series R 000, G 255, B 000 Aluminium sheets: 5xxx series R 204, G 255, B 204 Aluminium extrusion profiles R 153, G 204, B 000 1.7 Cast aluminium R 051, G 153, B 102 Magnesium R 255, G 255, B 000 Plastics Fibre reinforced plastics R 255, G 000, B 000 Duroplastics, including Sheet Molding Compound (SMC) R 255, G 153, B 000 Thermoplastics R 153, G 051, B 000 0.9 Other materials, namely:_________________________________________________ R 192, G 192, B 192 The following graph may serve as a guide to locate the properties of the metallurgical steel classes: 0 400 800 1.200 1.600 2.000 0 200 400 600 800 1.000 1.200 1.400 Tensile Strength /MPa Yield Strength /MPa HSLA BH Low Strength Steel High Strength Steel Ultra High Strength Steel Advanced High Strength Steel CP MS PHS Press Hardened Steel Mild TRIP DP HSIFEuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 4 3. Stiffness data Measured / Calculated 1st Eigenfrequency trimmed body: 26 Hz 2nd Eigenfrequency trimmed body: 27 Hz 1st Eigenfrequency body*: 40 Hz 2nd Eigenfrequency body*: 43 Hz *Parts included in the measurement/calculation of the body frequencies: Body in white with windshield and front bumper beam, without doors and decklid/liftgate Static torsional stiffness: 18,588 Nm/° Static bend stiffness: 11,200 Nm/mm 4. Contact area = track (1.546 m) x wheelbase (2.634 m) = 4.072 m 25. Joining processes used in the body shop, including all bought-in parts and sub-assemblies Joining technique Number of joints Weldspot Calculation or length of seams equivalents (WSE) Spot welds 3676 3676 1:1 Arc welding 0.856 m 43 20 mm = 1 WSE Laser welding 2.940 m 196 15 mm = 1 WSE Conventional brazing 1.032 m 52 20 mm = 1 WSE Laser brazing 3.094 m 104 30 mm = 1 WSE Adhesive joining 29.620 m 592 50 mm = 1 WSE Rivets 1 joint = 1 WSE Clinch-spots 1 joint = 1 WSE Screws (incl. flow drills) 61 61 1 joint = 1 WSE Total WSE: 4724 EuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 5 6. Production concept Process stability/availability: 85 % = total up-time in the body shop Re-tooling or re-use factor: n. sp. = [1 – Project investment excluding operational costs / “all new“] x 100 with ?all new“ = Value of the total installed investment Degree of mechanisation: 92 % = Automated Work Content* / Total Work Content* * Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operations Bodyshop-Index BSI n. sp. * model the of WSE Total ] units/hour [car model the of production net [€] model specific the for investment additional [€] re architectu , investment project × + =* as calculated in section 5 No. of production sites: 1 namely in: Cassino, Italy Intended production volume: 91,000 units/year Car body production lead time: 3h 25 minutes = the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including car body interim storage** ** More accurate definition (Harbour): ? Start counting when work begins at the first station of the underbody (motor compartment or rear floor, whichever station begins first). ? The end of the measurement is the beginning of the delivery from body in white to the paint shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer. Cycle time (mainline bodyshop): 71 seconds Degree of material utilisation/scrap rate: 99 % Total number of parts in the BIW: 354 Number of parts, including external parts, in weight classes 5 kg: 12 (all assemblies broken down into their component parts) EuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 6 7. Targeted market regions and origin of build… ….of the vehicle presented at the EuroCarBody: Targeted market region(s): Europe Origin of build: Cassino, Italy 8. Development strategies / initial propositions Specific aims of the development: Top performance in Euro NCAP rating, reduced weight / CO 2emission Specific improvements reached compared to the predecessor: Reduced weight in spite of higher performance, better handling performance, better insurance class, best-in-class passive safety Specific comparisons to direct competition in the market: Best-in-class passive safety and handling 9. Damage and repair strategy Qualitative description of the repair strategy: n. sp. Engine variant Insurance classification gasoline 88 kW 18 gasoline 125 kW 20 gasoline 173 kW 25 JTDM 77 kW 19 JTDM 125 kW 22 RCAR basket of parts*: Front: bumper fascia, bumper beam, lower crash can, lower load path, front end module, head lamp, hood, fender, front door. Rear: bumper fascia, bumper beam, rear closure. * Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and rear, respectively). See http://www.rcar.org/Papers/Procedures/rcar_test_protocol_angled_barrier.pdf EuroCarBody 2010, Benchmarking Data Summary Alfa Romeo Giulietta 7 10. Additional information: Crash performance data (if available at the time of the presentation): Euro NCAP No. of stars 5 Adult 34.7 Pts. = 97 % Front 15.4 Pts. S i d e 8 . 0 P t s . P o l e 7 . 9 P t s . R e a r 3 . 4 P t s . Child 41.6 Pts. = 85 % Pedestrian 22.6 Pts. = 63 % Safety Assist 6.0 Pts. = 86 % Development time: 15 months = time from design freeze to SOP/job one Life cycle analysis data: n. sp.
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