ANALYSIS RESULTS SUMMARY:

Toyota Tundra 20% Front Seat

FMVSS 207/210 – April-07-05

Work Order: 233.41860.001.G

FEA Design Level #: 14
Load Case Iteration #: 35,36
Template Revision: 1 Analyst (Employer): Ashish (Altair)
Revision Date: 01/01/05

April/07/05 1 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

I. Conclusions and Recommendations

Design 14 Iteration 35
• The Toyota Tundra 20% front seat withstands the 207/210 load case.
• No structural failure observed under the 207/210 load case.
• Maximum torque on right side recliner is 2888 Nm, where as maximum torque on left side recliner is 1045 Nm.

Design 14 Iteration 36
• The Toyota Tundra 20% front seat withstands the 207/210 load case.

• No structural failure observed under the 207/210 load case.

• Maximum torque on right side recliner is 2266 Nm, where as maximum torque on left side recliner is 912 Nm.

April-07-2005 2 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

II. Design Level and Model Description

Design Level 14 and Iteration 35
From the design 14 Iter 32 model: following changes has been done
1) CG loading change as per New FMVSS with distribution bar .
2) Lap block change to narrow mga lap block.

L-shaped steel channel 40x40xt4.

April-07-2005 3 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

II. Design Level and Model Description

Design Level 14 and Iteration 36
From the design 14 Iter35 model: following changes has been done
1) The shoulder and lap belt load reduce to 100% of FMVSS standard (from 120%). (13500N)
2) The CG load reduce to 100% of FMVSS standard (from 120%).(3551 N)

April-07-2005 4 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14:

Welds between outer and inner RH cushion bracket

added as per design11 iteration 19.

April-07-2005 5 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
Design 14 Iteration 35

Material and Thickness information for Major Components

April-07-2005 6 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

2-D seat belt

Back tube

Retractor mounting bracket

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

April-07-2005 7 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

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

Design 14 Iteration 35

Deformed Shape of Seat Deformation plot with un-deformed geometry

FMVSS 207/210 load results

April-07-2005 8 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

III. Detailed Analysis Results Pictures shown after structure is stabilized at 100% loading.
Design 14 Iteration 36

Deformed Shape of Seat Deformation plot with un-deformed geometry

FMVSS 207/210 load results

April-07-2005 9 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 35

Resultant Deflection contour

FMVSS 207/210 load results
April-07-2005 10 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

X-Component Design 14 Iteration 35 Z-Component

X and Z Deflection contour

FMVSS 207/210 load results
April-07-2005 11 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
Design 14 Iteration 35 Contour shown at stabilized time

The von Mises stress contour of complete seat

FMVSS 207/210 load results
April-07-2005 12 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 35 Contour shown at stabilized time

The effective plastic strain contour of complete seat

FMVSS 207/210 load results

April-07-2005 13 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 36

Resultant Deflection contour

FMVSS 207/210 load results
April-07-2005 14 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

X-Component Design 14 Iteration 36 Z-Component

X and Z Deflection contour

FMVSS 207/210 load results
April-07-2005 15 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
Design 14 Iteration 36 Contour shown at stabilized time

The von Mises stress contour of complete seat

FMVSS 207/210 load results
April-07-2005 16 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 36 Contour shown at stabilized time

The effective plastic strain contour of complete seat

FMVSS 207/210 load results

April-07-2005 17 W.O. # 233.41860.001.G
 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Analysis Outputs Under FMVSS Loading, Steady-State

Conditions - Belt tensions at the attachment points
Design 14 Iteration 35

LH side 16626 N
Lap belt
RH side 8890 N
Shoulder belt Upper Shoulder Belt Tension (Belt Exit Point) 8231 N

Design 14 Iteration 36

LH side 13781 N
Lap belt
RH side 7751 N
Shoulder belt Upper Shoulder Belt Tension (Belt Exit Point) 7118 N

April-07-2005 18 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 35

April-07-2005 19 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 36

April-07-2005 20 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 35

A = 39044 SR = 10710

LH cushion rear
A = 49586.4 SR = 12842

RH cushion front
A = 42071 SR = 5531.42
LH cushion front
A = 34625 SR = 4023.27
A = axial force, SR = shear resultant

April-07-2005 21 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Maximum Bolt forces at floor mounting locations

RH cushion rear Design 14 Iteration 36

A = 36771 SR = 10061.3

LH cushion rear
A = 46537 SR = 11745

RH cushion front
A = 38835 SR = 4800
LH cushion front
A =33398.3 SR = 3828.51
A = axial force, SR = shear resultant

April-07-2005 22 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

IV. Test Set-up and Acceptance Criteria

Design 14 Iteration 35,36

Generic JCI shoulder

block
Belt exit point
Generic JCI shoulder clevis

Retractor
mounting point.
Generic JCI lap block

CG bars

Load Distribution bar

Note: The “narrow mga lap block” is used for the center lap block

April-07-2005 23 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 35

16200 N

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.

April-07-2005 24 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36

Design 14 Iteration 35

13500 N

3551 N

• Seatback in design position.

• Load levels shown are at FMVSS (13500N). In the analysis, the applied loads are
held FMVSS.
• The shoulder and lap belt loading =13500 =13500 N
• The CG loading = 20xgxmass= 20x9.81x18.1 kg = 3551 N

Acceptance Criteria:
• Seat must hold FMVSS loads without any part fracture.

April-07-2005 25 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
Design 14 Iteration 35,36

April-07-2005 26 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
Design 14 Iteration 35,36

April-07-2005 27 W.O. # 233.41860.001.G

 Seat: Toyota Tundra 20% Front Seat FEA Design Level #: 14
Load Case: FMVSS 207/210 Load Case Iteration #: 35,36
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)

April-07-2005 28 W.O. # 233.41860.001.G