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Application of a Novel Metal Folding Technology for Automotive BiW Design
Abstract:
The Deep Orange [1] initiative is an integral part of the automotive graduate program at Clemson University International Center for Automotive Research. The initiative was developed to provide the graduate students with hands-on experience of the knowledge attained in the various engineering disciplines and related disciplines (such as marketing and human factors psychology). For the 3rd edition of Deep Orange, the goal was to develop a blank sheet hybrid mainstream sports car concept targeted towards the Generation Y (Gen Y) market segment.
The objective of this paper is to explain the unique body-in-white (BiW) concept that offers space for 6-passengers and includes a dual-mode hybrid all-wheel drive powertrain. An additional objective of the project was to develop and showcase a body-in-white concept that will eliminate metal stamping and high capital investments associated with this technology (such as dies and stamping tools). It was chosen to explore Industrial Origami's patented technology that uses lighter gauge material folded into complex, innovative, high load-bearing structures, formed with simple, low cost fixtures, at the point of assembly.
Developing the topology, geometry and functionality of the BiW required an intensive collaboration between design students and chassis, powertrain, NVH and occupant packaging engineering students while carefully balancing functional properties, design space, cost and weight. Once the properties and design targets were met, the complete sheet Folded Metal Technology (FMT) design was realized using aluminum and structural adhesives. In addition to describing the conceptual analyses, the paper will also elaborate on the final realization of the BiW concept.
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