Steel manufacturing has been a critical component in the automotive manufacturing industry since the material was first used to replace the heavy wood automobile frames of the 19th century. Today, a top steel producing company is taking its role in the automotive industry to new heights, capitalizing on advanced technology, state-of-the-art modeling equipment and the expertise of top innovators.
ArcelorMittal Research and Development’s (R&D) crash test computer simulation program is a collaborative effort with automakers to help them optimize time, safety and cost savings. ArcelorMittal researchers tap into the power of technology for analysis and the development of new products.
“We have a methodology for crash simulations to see how the steel performs during a crash. We can test different grades and each grade’s own specific properties to propose new designs based on different grades that we can develop in our facility,” said Yannis Kheyati, senior engineer with ArcelorMittal R&D. Kheyati noted the computer simulations are less costly and time consuming for automotive manufacturers rather than physical crash tests. “With these simulations, we can predict the future as we see how the structure will perform or react in the models and compare it with other models.”
Detailed Analysis
David White, Director of Product Development and Process Research Global for ArcelorMittal R&D, said the company has been involved in simulations for decades, but rapidly-evolving technology over the last few years has made a remarkable difference in what they can achieve now.
“The difference is in the sophistication of the simulations. They have gotten so much better,” he said. “With the simulations that we perform today, it’s hard to tell them apart from a real physical crash.”
ArcelorMittal R&D employs the help of revolutionary equipment used to supply the information to develop the simulations. Those tools include scanning electron microscopes, X-ray photo electron spectrometers, spectrophotometers and micro-X-ray fluorescence. The simulator experts at ArcelorMittal are able to take the results and apply them to a solution. Kheyati said the instruments provide very detailed information about the microstructure of the steel with the ability to detect incredibly small details, imperfections and inclusions that may ultimately affect performance.
“With all of this technology, it’s like the gates have been opened for software developers to get deeper and make more complex methodologies for failure modes and for understanding the models,” he said. “With these tools, we have more power and more memory and better performance to predict our models more precisely.”
The simulations, which can start seven years before a automaker plans to commercially release a vehicle, provide insights to manufacturers about the performance of the innovative steel solutions being proposed. In a collaboration between ArcelorMittal’s research and development department and the auto manufacturer, many important factors can be considered.
“Our ultimate goal is to show that in this application solution that has been designed, it’s going to be an improvement for the automakers,” said White. “It’s going to improve safety. It’s going to reduce the cost of the fabrication. It’s going to reduce the weight of the vehicle, which is good for fuel economy. We want to show that our steel using these designs is going to be an improvement. Ultimately, we want to sell more steel to the automakers, and we want to give them the best innovative products.”
Seeing is Believing
Robert Joseph, Operations Manager for ArcelorMittal Global Research and Development East Chicago Laboratories, said the computer simulations also offer a higher level of understanding among the automakers, who are able to see, rather than just being told, what the design process and impact of what ArcelorMittal’s lightweight steel solutions can have on their operations.
“I think the visualization aspect of it is something that we are understanding, too. There’s a lot to be said when you are a customer who may not be as involved in the technical side,” said Joseph. “When they see something hit a wall, and I watch their reaction, I can tell it’s very visceral for them. It portrays a lot. You can definitely get a sense of how tough the material is, how it performs by watching the visualization of it actually happening.”
ArcelorMittal’s simulation initiative is now also being applied to electric vehicle manufacturing, said White, who also noted that the simulations have also been a major contributor to the company’s ability to strengthen their multi-part integration services. It’s one more way, Joseph noted, ArcelorMittal remains relevant with the trends of the future of the automobile industry.
“Our laboratory allows us to actually put hands on what is going on -- on top of the hypotheticals. We can analyze it, and we put our fingers on it,” Joseph said. “That is something that we do here we feel is pretty unique and pretty wonderful in the big picture of things. In addition to the discussions about innovation here, we showcase it, and we put it into action – up close and personally.”