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강연식(Yeonsik Kang),이홍우(Hongwoo Lee),김재현(Jaehyun Kim),정경환(Kyunghwan Chung),이현영(Hyunyoung Lee),남재복(Jaebok Nam) 한국자동차공학회 2012 한국자동차공학회 학술대회 및 전시회 Vol.2012 No.11
POSCO developed a new body concept for electric vehicle (PBC-EV, POSCO Body Concept ? Electric Vehicle) with the aim to identify requirements of new steel grades for electric vehicle and to provide cost efficient steel solutions to customer. The objectives are achieved by advanced steel technologies and engineering design optimization with the best attributes of steel ? its design flexibility, strength, formability and low manufacturing cost. PBC-EV features steel body structure designs that reduce weight to 218kg by 26 percent over a benchmark body of 296kg. The weight reduction has been realized through the use of advanced high strength steel grades by 65% of total body weight. The steel grades include TWIP, 2Gipa grade HPF steels as well as DP, CP and TRIP steels. A number of steel application technologies were also adopted to take the benefit of advanced steels. New forming technologies such as tailored hot press forming and multi-directional roll forming were applied as well as conventional manufacturing methods. Even though there is a cost premium associated with the use of higher grade steels, the consequently achieved weight savings and the optimal use of forming process minimize the overall cost increase of manufacturing and assembly. The total life cycle emission of PBC-EV is reduced by nearly 50 percent comparing to the benchmark internal combustion engine vehicle. These are accomplished while meeting a broad list of global safety requirements such as US FMVSS, IIHS and EuroNCAP. No damage of battery cell in the crash simulations is observed. In the last stage hardware demonstration was done by building BIWs (Body-in-White) excluding opening parts and fenders. It is very important for automakers to avoid unintended consequences by using eco-friendly steel technologies for advanced powertrain vehicle. With this project advanced steel solutions which are not only lighter and safer but greener can be provided to automakers.