2009 Dodge Journey Body Structure
Equipment and Tool Institute
June 18, 2008
Andrew Poulios
Body Structures Engineering
6/18/2008
Created by Andrew Poulios
Body Material – Steel Summary
KEY:
6/18/2008
AHS
S
UHS
S
HS
AL
PL
Created by Andrew Poulios
Body Material - Parts Summary
Breakdown of Material Usage
Part Usage*:
2009 Dodge Journey:
Material Part Quantity
- Hot Stamp Boron Steel…………. 10 Parts
- B-Pillar
- B-Pillar Reinforcement
- Windshield Frame
- Door Beams
- Dual Phase 340/590 Steel……… 21 Parts
40 KSI
50 KSI
80 KSI
DP 590
Hot Stamp Boron
Aluminum
SMC
Mild
- Front Rails
- Dash Crossmember
- Rear Rails
- Tunnel Cap
- Front Floor Crossmember
- 80 ksi HSLA steel……………….. 9 Parts
- 50 ksi HSLA steel……………….. 40 Parts
- 40 ksi HSLA steel……………….. 13 Parts
- Aluminum………………………… 6 Parts
- SMC Fiberglass…………………. 3 Parts
Breakdown of BIW Components by Mass:
- 57.6% Mild Steel
- 38.4 % mix of hot stamp, dual phase and high strength steel
- 2.5% SMC (Fiberglass)
- 1.5% Aluminum
6/18/2008
Created by Andrew Poulios
Steel Types
HS Steel
AHHS: Dual Phase
Parts:
Front Rails:
Dash x-member:
Tunnel cap:
Front floor x-member:
Rear floor sidemembers
Front seat x-members
Rear Rails
8 parts
1 part
1 part
1 part
2 parts
2 parts
6 parts
Total
21 parts
Parts:
Galvanneal Coated Dual Phase 340/590 MPa Steel:
• Front rails
• Tunnel Cap
• Rear rails
• Rear floor sidemembers
• Dash crossmember
• Front Seat crossmembers
• Front floor crossmember
Benefits
• Weight optimization
●
Impact energy absorption
Ft Tunnel Rail
Shock Cap Reinf
Roof Side Rail
B-Pillar Inner
C-Pillar Lower Reinf
Ft Dr Upper Hinge Assy
RR Dr Upper Hinge Assy
2nd Row Seat Anchor Plt
RR Susp Reinf
Ft Rt Crush Can Inner
Ft Lt Crush Can Outer
Hood Hinge
RR Bumper Beam
Sill Outer
Roof Bow
Cowl Side
Body Ft Hinge Pillar
B-Pillar Lower Reinf
Ft Dr Lower Hinge Assy
RR Dr Lower Hinge Assy
Fuel Tank Attach Bkt
RR Spring Cap
Shipping Tie Down Bkt
Ft Rt Crush Can Outer
Ft Lt Crush Can Inner
Ft Bumper Beam
Sill Inner
Sill Reinf
Total:
Benefits
• Weight optimization
28 parts
●
Impact energy absorption
UHHS: Hot Stamped
Parts:
- Door Impact Beams
- B-Pillar
- B-Pillar Reinforcement
- Windshield Frame
Benefits
- Improves roof crush strength
- Improves door crush resistance
- Optimizes weight distributions
- Provides passenger compartment Integrity during front and side impact modes
6/18/2008
Created by Andrew Poulios
Body Structure Highlights
Highlights of Dodge Journey’s body structure include the following features:
• Dodge Journey’s body structure contains a combined 38.4% by mass of hot stamped
and high-strength steels for optimized weight and structural performance.
• The next generation of elastic adhesives from Dow Automotive adds strength to joints
during an impact while being easier to use during the assembly process compared to
the first generation “Blue Glue” that was first introduced on Dodge Caliber
• Effective joint designs create a rigid structure, minimizing NVH inputs to the passenger
compartment and increasing body stiffness through enhanced structural continuity
• More crush space added to the engine box by moving the power-train 50mm forward
• From the B-pillar forward, Dodge Journey’s upperbody has common architecture with
Sebring/Avenger with components sized appropriately for structural performance
• The doors feature several reinforcements for side-impact protection:
• Stamped belt reinforcements on the front doors and rear doors
• Hot-stamped beams in front and rear doors
• Stamped reinforcements that connect the belt reinforcements to the hot stamped beams
6/18/2008
Created by Andrew Poulios
Load Path: Underbody
*Similar to JS41
Jack Points
• Extensive use of dual-phase steels in the front and rear rails, tunnel reinforcement and sills
permit these components to handle greater loads than conventional steels for more effective
impact energy management while still being relatively easy to stamp and control dimensionally
KEY:
6/18/2008
AHS
S
UHS
S
HS
AL
PL
Created by Andrew Poulios
Load Path: Upperbody
• High strength and hot stamped boron steels are used extensively in the body side inner for
effective side impact energy management and
• Hot stamped steel A-pillar and B-pillar reduce upper body weight by 30 lb. (14kg) compared
to mild steel equivalents
KEY:
6/18/2008
AHS
S
UHS
S
HS
AL
PL
Created by Andrew Poulios
Bumper System
Feature Highlights
• New lighter “D-section” bumper assemblies compared to the prior “B section” bumper assemblies used on
Chrysler Group vehicles are designed to perform energy management in a small space
• The bumpers are designed to accommodate the most stringent of truck classified vehicle requirements.
(Dodge Journey is classified as an SUV/light truck)
• The front bumper is contained in the front end module. The new, lighter D-section bumper assembly features
80 Ksi roll formed steel for vehicle protection in low speed impacts.
6/18/2008
Created by Andrew Poulios
Front End Module
Dodge Journey’s front end module represents the next phase in evolution from the Chrysler Sebring/Dodge
Avenger front end module. This front end module features the highest level of component integration to date within
the Chrysler Group.
FEM
FEM COMPONENTS
Features and Benefits
• The benefits of this attachment scheme are complexity reduction and ease of service by eliminating many
unique fasteners.
• There are one screw attachment and snap-in features for many components that are integrated in the module.
• Front-end module attaches to the body at bumper beam and top (highlighted in green) attaches to load beam
• The components mount on a hybrid structural armature that spans the front of the vehicle, replacing multiple
steel parts that are traditionally welded together.
• The backbone starts with a stamped steel C-section beam over molded with 20 percent glass-filled
polypropylene. A latticework mesh inside the C-section provides the component’s structure.
6/18/2008
Created by Andrew Poulios
QUESTIONS
6/18/2008
Created by Andrew Poulios