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ANALYSIS RESULTS SUMMARY:

Toyota Tundra 20% Front Seat


FMVSS 207/210 – May-26-05

Work Order: 233.41860.001.G


FEA Design Level #: 32
Load Case Iteration #: 63
Template Revision: 1 Analyst (Employer): Ashish (Altair)
Revision Date: 01/01/05

May/26/05 1 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

I. Conclusions and Recommendations


Design 32 Iteration 63
• The Toyota Tundra 20% front seat withstands the 207/210 load case.
• Maximum plastic strain in console sub structure is around 44%.Failure plastic strain for ABS
material is around 16%.There are some region in console substructure where plastic strains are
more than 16%.These high plastic strain region in console substructure may crack under the given
load case. 1.306.Please refer slide12.
• Localized failure observed on RH cushion bracket in bolt region. Maximum Plastic strain on RH
cushion bracket is 2.819.Failure plastic strain for RH cushion bracket is 1.306.Please refer slide11.
• Maximum torque on right side recliner is 2857 Nm, where as maximum torque on left side recliner
is 1070 Nm.

May-26-2005 2 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

II. Design Level and Model Description


Design Level 32 and Iteration 63
From design 31 Iter62 model model: following changes has been done
1) Seat back bushing added on Tower support bracket.

May-26-2005 3 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Design 32:

May-26-2005 4 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63
Design 32 Iteration 63

Material and Thickness information for Major Components

May-26-2005 5 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

2-D seat belt

Back tube

Retractor mounting bracket

Belt routing over retractor mtg. bracket, back tube and wire belt exit

May-26-2005 6 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

III. Detailed Analysis Results Pictures shown after structure is stabilized at 100% loading.

Design 32 Iteration 63

Deformed Shape of Seat Deformation plot with un-deformed geometry

FMVSS 207/210 load results

May-26-2005 7 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Design 32 Iteration 63

Resultant Deflection contour


FMVSS 207/210 load results
May-26-2005 8 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63
Design 32 Iteration 63 Contour shown at stabilized time

The von Mises stress contour of complete seat


Note: Material yield stress is not 980 MPa FMVSS 207/210 load results
May-26-2005 9 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Design 32 Iteration 63 Contour shown at stabilized time

The effective plastic strain contour of complete seat

FMVSS 207/210 load results


May-26-2005 10 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Design 32 Iteration 63

The effective plastic strain contour of Cushion support bracket RH

FMVSS 207/210 load results


May-26-2005 11 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

The effective plastic strain contour of Console sub-structure (ABS)

FMVSS 207/210 load results


May-26-2005 12 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Analysis Outputs Under FMVSS Loading, Steady-State


Conditions - Belt tensions at the attachment points
Design 32 Iteration 63

Lap belt LH side 18139 N


RH side 8647 N
Shoulder belt Upper Shoulder Belt 7162 N
Tension (Belt Exit
Point)

May-26-2005 13 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Design 32 Iteration 63

May-26-2005 14 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

Maximum Bolt forces at floor mounting locations

RH cushion rear Design 32 Iteration 63


A = 38591.5 SR = 9124.06

LH cushion rear
A = 33497.1 SR = 14740.6

RH cushion front
A = 27433.1 SR = 2695.63
LH cushion front
A = 34330.1 SR = 3476.26
A = axial force, SR = shear resultant

May-26-2005 15 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

IV. Test Set-up and Acceptance Criteria


Design 32 Iteration 63

Generic JCI shoulder


block
Belt exit point
Generic JCI shoulder clevis

Generic JCI lap block

CG bars

May-26-2005 16 W.O. # 233.41860.001.G


Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63

This iteration used Test Set-Up Revision Level 0 (for analysis W.O. # 233.41800.001.G).
Attached is the Test Set-Up Specification Sheets that details this set-up condition:

16200 N
Acrobat Document

4261 N

• Seatback in design position.


• Load levels shown are at FMVSS+ 20% (16200N). In the analysis, the applied
loads are held FMVSS + 20% load level.
• The shoulder and lap belt loading =13500x1.2=16200 N
• The CG loading =(20xgxmass)x1.2=(20x9.81x18.1 kg)x1.2=4261 N

Acceptance Criteria:
• Seat must hold FMVSS + 20% loads without any part fracture.
• Mechanisms must not fail or disengage (analysis cannot predict this, other than by
recovering loads from the analysis and comparing to the mechanism’s rated strength).
May-26-2005 17 W.O. # 233.41860.001.G
Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 32
Load Case: FMVSS 207/210 Load Case Iteration #: 63
V. Analysis Methods Summary
The following standardized JCI methods were used for this analysis iteration(s):
JCI Analysis Method Revision Comments/Exceptions
Level
207/210 General Analysis 1
Procedure (1/1/05)
(207210_Analysis_Procedure.pdf)

207/210 Body Block Positioning 1


Procedure (1/1/05)
(Belt_Lengths_and_Body_Block_Positioning_Pr
ocedure.pdf)

Dyna General Procedure 1


(Dyna_General.pdf) (1/1/05)

Forming Mapping Procedure 1


(Mapping_Forming_Results.pdf) (1/1/05)

Material Property Curves 0


(10/1/04)

Detailed Bolt Modeling Macro 2


(01/21/05)

May-26-2005 18 W.O. # 233.41860.001.G