ANALYSIS RESULTS SUMMARY:

Toyota Tundra 20% Front Seat

FMVSS 207/210 – May-02-05

Work Order: 233.41860.001.G

FEA Design Level #: 27
Load Case Iteration #: 57
Template Revision: 1 Analyst (Employer): Ashish (Altair)
Revision Date: 01/01/05

May/02/05 1 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

I. Conclusions and Recommendations

Design 27 Iteration 57
• The Toyota tundra 20% front seat RH cushion bracket is on the point of buckling under the 207/210 load case.
• Localized failure observed on RH cushion bracket in bolt region. Maximum Plastic strain on RH cushion
bracket is 1.327.Failure plastic strain for RH cushion bracket is 1.306.Please refer slide12.
• Maximum torque on right side recliner is 2704 Nm, where as maximum torque on left side recliner is 1053 Nm.

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

II. Design Level and Model Description

Design Level 27 and Iteration 57
From design 27 Iter 55 model : following changes has been done.
1) RH inner cushion bracket material change to 420XF.
Note: Forming done on this part and forming results are included in FMVSS207/210 run.

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Design 27:

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57
Design 27 Iteration 57

Material and Thickness information for Major Components

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

2-D seat belt

Back tube

Retractor mounting bracket

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

May-02-2005 6 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

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

Design 27 Iteration 57

Deformed Shape of Seat Deformation plot with un-deformed geometry

FMVSS 207/210 load results

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Design 27 Iteration 57

Resultant Deflection contour

FMVSS 207/210 load results
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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

X-Component Design 27 Iteration 57 Z-Component

X and Z Deflection contour

FMVSS 207/210 load results
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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57
Design 27 Iteration 57 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
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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Design 27 Iteration 57 Contour shown at stabilized time

The effective plastic strain contour of complete seat

FMVSS 207/210 load results

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Design 27 Iteration 57

Failure plastic strain for RH cushion bracket is 1.306

The effective plastic strain contour of Cushion support bracket RH

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Analysis Outputs Under FMVSS Loading, Steady-State

Conditions - Belt tensions at the attachment points
Design 27 Iteration 57

LH side 18130 N
Lap belt
RH side 8635 N
Upper Shoulder Belt
Shoulder
Tension (Belt Exit 7339 N
belt
Point)

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Design 27 Iteration 57

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

Maximum Bolt forces at floor mounting locations

RH cushion rear Design 27 Iteration 57

A = 38366.2 SR = 8414.35

LH cushion rear
A = 37240.7 SR = 1456.4

RH cushion front
A = 37086.9 SR = 4038.07
LH cushion front
A = 30462.7 SR = 15611
A = axial force, SR = shear resultant

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

IV. Test Set-up and Acceptance Criteria

Design 27 Iteration 57

Generic JCI shoulder

block
Belt exit point
Generic JCI shoulder clevis

Generic JCI lap block

CG bars

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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57

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).
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 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 27
Load Case: FMVSS 207/210 Load Case Iteration #: 57
V. Analysis Methods Summary
The following standardized JCI methods were used for this analysis iteration(s):
Revision
JCI Analysis Method Comments/Exceptions
Level
207/210 General Analysis
1
Procedure (1/1/05)
(207210_Analysis_Procedure.pdf)

207/210 Body Block Positioning

Procedure 1
(1/1/05)
(Belt_Lengths_and_Body_Block_Positioning
_Procedure.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)

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