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ArcelorMittal has identified a catalogue of solutions for the subframe and lower control arms of a plug-in hybrid vehicle (PHEV). The technically powerful solutions can also be adapted for different powertrains including battery electric vehicles (BEVs). A range of ferrite-bainite (FB) and complex phase (CP) grades have been utilized due to their specific properties which make them ideal for chassis applications. The optimized S-in motion® solutions offer OEMs the opportunity to create lighter, safer, and more environmentally friendly vehicles.
The steels
The Complex Phase and Ferrite-Bainite grades selected for the front chassis components offer:
- Good formability for the complex geometries required in chassis parts
- Increased stiffness with the possibility to create deeper flanges
- Cut-edge sensitivity and good hole expansion
All selected grades offer:
- Good fatigue properties
- Good welding properties (GMAW)
Complex Phase (CP)grades
HR-CP800SF – hot rolled grade with a minimum tensile strength up to 780 MPa
HR-CP980SF – an emerging hot rolled grade witha minimum tensile strength of up to 980 MPa
Ferrite-Bainite grade
HR-FB590 – hot rolled grade with a minimum tensile strength up to 590 MPa.
Lower control arm
The S-in motion® lower control arms were benchmarked against single- and double-shell, forged steel, and HPDC designs currently used in production vehicles.
Bushing direction is a key consideration in the design of the lower control arm. HR-CP800SF and the emerging HR-CP980SF grade were developed to enable OEMs to stamp both vertical and horizontal bushings.
Complex Phase steels offer high stretch flangeability. HR-CP800SF offers high edge ductility with a hole expansion ratio (HER) of at least 50 percent.
Single shell with vertical or horizontal bushing
780 MPa solution
-
Grade: HR-CP800SF
Gauge: 3.5 mm
Mass: 2.13 kg*
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Grade: HR-CP800SF
Gauge: 3.7 mm
Mass: 2.27 kg*
*Mass without bushes or ball joint
Double shell with vertical bushing
780 MPa solution
-
Grade: HR-CP800SF
Gauge: 3.0 mm
Mass: 3.05 kg*
-
Grade: HR-CP800SF
Gauge: 3.0 mm
Mass: 2.58 kg*
*Mass without bushes or ball joint
Front subframe
The S-in motion® front subframe for PHEVs can be adapted for both small and large front subframes.
-
-
Proof load cases
-
Top Plate
Grade: HR-CP800SF
Gauge: 1.8 mm
Lightening holes based on topology optimization.
-
Bottom Plate
Grade: HR-CP800SF
Gauge: 2.3 mm
Lightening holes based on topology optimization.
Front body-mount pillar
-
Front plate
Grade: HR-FB590
Gauge: 1.9 mm
-
Rear plate
Grade: HR-FB590
Gauge: 1.8 mm
Forming validations
To test the performance of the HR-CP800SF and HR-CP980SF grades in production, forming simulations were carried out on the lower control arm and subframe top plate. The simulations used ArcelorMittal data and criteriatohighlight the global and local formability of these grades.
Forming – lower control arm
Forming – subframe top plate
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