This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Body-in-White Reinforcements for Light-Weight Automobiles
Technical Paper
2016-01-0399
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Automotive OEMs are proactively working on vehicle light-weighting, powertrain optimization, alternate/renewable energy sources and combinations of the three to meet challenging corporate average fuel economy (CAFE) standards. Light-weighting of the body-in-white (BIW) is an obvious choice for vehicle light-weighting as this structure contributes to more than 30-35% of the total weight of a car. Changing manufacturing and assembly lines requires substantial investment. As such, OEMs are exploring short-term light-weighting strategies that do not require any major changes to the BIW. Local reinforcement for the BIW are pertinent solutions that does not require any major changes in the existing assembly lines.
This paper focuses on the development of BIW reinforcement solutions using engineering thermoplastic materials that can be mounted at appropriate locations on a vehicle’s BIW to achieve significant weight savings without compromising crash performance. Various design and material configurations - including plastic, metal-plastic and composite-plastic structural members - mounted on the BIW are evaluated through CAE studies for various crash scenarios such as high-speed frontal crashes, side impact, pole impact and rollover. The CAE studies, performed using generic vehicle models, quantify the potential weight-savings in a vehicle by either replacing the existing reinforcements using a lighter system or by incorporating additional reinforcements in the BIW by down-gauging the existing BIW. Approaches to correlate the CAE studies using component level testing and validation of generic reinforcements are also investigated. Data from all of this work indicate that the use of BIW reinforcements can achieve significant weight reduction (∼ 1.5%) in a vehicle, while also ensuring no compromise in crash performance.
Recommended Content
Authors
Citation
Munjurulimana, D., Kulkarni, A., Nagwanshi, D., Thambi, J. et al., "Body-in-White Reinforcements for Light-Weight Automobiles," SAE Technical Paper 2016-01-0399, 2016, https://doi.org/10.4271/2016-01-0399.Also In
References
- https://www.transportation.gov/mission/sustainability/corporate-average-fuel-economy-cafe-standards Nov. 2015
- http://www.theicct.org/blogs/staff/improving-conversions-between-passenger-vehicle-efficiency-standards Nov. 2015
- http://www.designnews.com No. 2015
- Buchholz , K. Materials lead the way to vehicle mass reduction SAE Automotive Engineering Magazine Aug. 30 2012
- Sah , S. , Bawase , M. , and Saraf , M. Light-weight Materials and their Automotive Applications SAE Technical Paper 2014-28-0025 2014 10.4271/2014-28-0025
- Makino , K. Advanced Requirements for Fuel Efficient Cars by Creating Efficient Body SAE Technical Paper 2011-01-0854 2011 10.4271/2011-01-0854
- Lei , F. , Chen , X. , Xie , X. , and Zhu , J. Research on Three Main Lightweight Approaches for Automotive Body Engineering Considering Materials, Structural Performances and Costs SAE Technical Paper 2015-01-0580 2015 10.4271/2015-01-0580
- Zhou , G. , Li , G. , Cheng , A. , Wang , G. et al. The Lightweight of Auto Body Based on Topology Optimization and Sensitivity Analysis SAE Technical Paper 2015-01-1367 2015 10.4271/2015-01-1367
- Lewis , A. , Keoleian , G. , and Kelly , J. The Potential of Lightweight Materials and Advanced Combustion Engines to Reduce Life Cycle Energy and Greenhouse Gas Emissions SAE Technical Paper 2014-01-1963 2014 10.4271/2014-01-1963
- Lightweight, heavy impact - McKinsey & Company Advanced Industries February 2012
- Nagwanshi D.K. , Parameshwara , A. , Bobba , S. , Marur , S.R , Marks , M.D Reinforced body in white and method of making and using the same U.S. Patent 2014/0203592 A1 Aug. 24 2014
- National Crash Analysis Center at George Washington University Finite Element Model Archive http://www.ncac.gwu.edu/vml/models.html Oct. 2014
- HyperWorks User Manual, Version 12.0 2012 Altair Incorporation www.altair.com
- Frontal full wall NHTSA 5677 http://www.ncac.gwu.edu/vml/archive/ncac/vehicle/yaris-v1m.pdf Nov. 2015
- Side impact crash worthiness evaluation, Crash test protocols test protocols (version VII) Insurance Institute for Highway Safety May 2014
- http://www.safercar.gov/staticfiles/safercar/NCAP/Side-Pole_TP_NCAP.pdf Nov. 2015
- Laboratory test procedures for FMVSS 216 Roof crush resistance -TP-216-05 November 16 2006
- LS-Dyna User Manual, Version 971 2006 Livermore Software Technology Corporation