The Multi Material Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of a US Department of Energy project DE-EE0005574. The project demonstrates the lightweighting potential of a five passenger sedan, while maintaining vehicle performance and occupant safety. Prototype vehicles were manufactured and limited full vehicle testing was conducted. The MMLV vehicle design, comprised of commercially available materials and production processes, achieved a 364kg (23.5%) full vehicle mass reduction, enabling the application of a 1.0-liter three-cylinder engine resulting in a significant environmental benefit and fuel reduction.
The three key requirements of structural performance evaluation for vehicle development are NVH, durability and safety. This paper presents the durability assessment of the MMLV design and prototype via CAE simulation of body-in-white structure, subframe and closure designs as well as the full vehicle field durability test at the Ford Michigan Proving Ground. The vehicle durability test assures the prototype meets the Ford Corporate Standard equivalent to 150,000 miles durability life while CAE simulation provides the durability map to assist field test examination.