Truck & Off-Highway Engineering - August 2023 - 26

Constructing
bus structures with
stainless steel
Base material
13.6% strain-hardening
was made entirely of carbon steel (S460) with a weight
of 3,600 kg (7,940 lbs.). Even without material substitution,
optimization enabled a useful weight saving of 116
kg (256 lbs.). When Forta H800 was used for the entire
structure, the mass of the structure was reduced by onethird,
saving 1,193 kg (2,630 lbs.). The rollover simulation
also showed that the wall thickness of the tubing could
be reduced from 4 mm to 2 mm (0.157 to 0.079 inches),
accounting for a large part of the weight saving.
The next stage was to examine a hybrid structure
24.3% strain-hardening
Figure 2: Hardening effect of Forta H-Series.
quasistatic loading; cyclic loading; torsional stiffness and NVH (noise, vibration
and harshness) - an important factor for passenger comfort and
driving dynamics; and rollover for compartment intrusion during a crash.
Results prove weight savings
Figure 4 shows the results of the simulations from a large number (thousands)
of experiments. For the reference case, a pure frame structure
56.8% strain-hardening
featuring both types of steel. Two alternatives were
examined, with S460 and then Forta H800 used for
the top mainframes. In the first case, the weight reduction
was 25%. When most of the upper section is created
in Forta H800, a 35% reduction was achieved.
That is a potential weight reduction of almost 1,300 kg
(2,866 lbs.). Furthermore, the volume of welding required
to create the structure is reduced by more than
50%. There also is a small lowering in the center of
gravity, which is beneficial for driving dynamics.
Cost impact
The cost impact of changing the frame material is
shown in Figure 5. The relative costs of different steels
can vary over time and according to market conditions,
Figure 3: Analysis of a generic bus design.
Figure 4: Summary of simulation results based on design of experiment (DOE) samples.
26 August 2023
TRUCK & OFF-HIGHWAY ENGINEERING
ALL IMAGES: OUTOKUMPU

Truck & Off-Highway Engineering - August 2023

Table of Contents for the Digital Edition of Truck & Off-Highway Engineering - August 2023

Truck & Off-Highway Engineering - August 2023 - INTRO1
Truck & Off-Highway Engineering - August 2023 - SPONSOR1
Truck & Off-Highway Engineering - August 2023 - CVRA
Truck & Off-Highway Engineering - August 2023 - CVRB
Truck & Off-Highway Engineering - August 2023 - CVR1
Truck & Off-Highway Engineering - August 2023 - CVR2
Truck & Off-Highway Engineering - August 2023 - 1
Truck & Off-Highway Engineering - August 2023 - 2
Truck & Off-Highway Engineering - August 2023 - 3
Truck & Off-Highway Engineering - August 2023 - 4
Truck & Off-Highway Engineering - August 2023 - 5
Truck & Off-Highway Engineering - August 2023 - 6
Truck & Off-Highway Engineering - August 2023 - 7
Truck & Off-Highway Engineering - August 2023 - 8
Truck & Off-Highway Engineering - August 2023 - 9
Truck & Off-Highway Engineering - August 2023 - 10
Truck & Off-Highway Engineering - August 2023 - 11
Truck & Off-Highway Engineering - August 2023 - 12
Truck & Off-Highway Engineering - August 2023 - 13
Truck & Off-Highway Engineering - August 2023 - 14
Truck & Off-Highway Engineering - August 2023 - 15
Truck & Off-Highway Engineering - August 2023 - 16
Truck & Off-Highway Engineering - August 2023 - 17
Truck & Off-Highway Engineering - August 2023 - 18
Truck & Off-Highway Engineering - August 2023 - 19
Truck & Off-Highway Engineering - August 2023 - 20
Truck & Off-Highway Engineering - August 2023 - 21
Truck & Off-Highway Engineering - August 2023 - 22
Truck & Off-Highway Engineering - August 2023 - 23
Truck & Off-Highway Engineering - August 2023 - 24
Truck & Off-Highway Engineering - August 2023 - 25
Truck & Off-Highway Engineering - August 2023 - 26
Truck & Off-Highway Engineering - August 2023 - 27
Truck & Off-Highway Engineering - August 2023 - 28
Truck & Off-Highway Engineering - August 2023 - 29
Truck & Off-Highway Engineering - August 2023 - 30
Truck & Off-Highway Engineering - August 2023 - 31
Truck & Off-Highway Engineering - August 2023 - 32
Truck & Off-Highway Engineering - August 2023 - 33
Truck & Off-Highway Engineering - August 2023 - 34
Truck & Off-Highway Engineering - August 2023 - CVR3
Truck & Off-Highway Engineering - August 2023 - CVR4
https://www.nxtbook.com/smg/sae/24TOHE12
https://www.nxtbook.com/smg/sae/24TOHE10
https://www.nxtbook.com/smg/sae/24TOHE08
https://www.nxtbook.com/smg/sae/24TOHE06
https://www.nxtbook.com/smg/sae/24TOHE04
https://www.nxtbook.com/smg/sae/24TOHE02
https://www.nxtbook.com/smg/sae/23TOHE12
https://www.nxtbook.com/smg/sae/23TOHE10
https://www.nxtbook.com/smg/sae/23TOHE08
https://www.nxtbook.com/smg/sae/23TOHE06
https://www.nxtbook.com/smg/sae/23TOHE04
https://www.nxtbook.com/smg/sae/23TOHE02
https://www.nxtbook.com/smg/sae/22TOHE12
https://www.nxtbook.com/smg/sae/22TOHE10
https://www.nxtbook.com/smg/sae/22TOHE08
https://www.nxtbook.com/smg/sae/22TOHE06
https://www.nxtbook.com/smg/sae/22TOHE04
https://www.nxtbook.com/smg/sae/22TOHE02
https://www.nxtbook.com/smg/sae/21TOHE12
https://www.nxtbook.com/smg/sae/21TOHE10
https://www.nxtbook.com/smg/sae/21TOHE08
https://www.nxtbook.com/smg/sae/21TOHE06
https://www.nxtbook.com/smg/sae/21TOHE04
https://www.nxtbook.com/smg/sae/21TOHE02
https://www.nxtbookmedia.com