This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
A Simple Approach to Selecting Automotive Body-in-White Primary-Structural Materials
Technical Paper
2002-01-2050
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
A simple strategy for building lightweight automobile body-in-whites (BIWs) is developed and discussed herein. Because cost is a critical factor, expensive advanced materials, such as carbon fiber composites and magnesium, must only be used where they will be most effective. Constitutive laws for mass savings under various loading conditions indicate that these materials afford greater opportunity for mass saving when used in bending, buckling or torsion than in tensile, shear or compression. Consequently, it is recommended that these advanced materials be used in BIW components subject to bending and torsion such as rails, sills, “A-B-C” pillars, etc. Furthermore, BIW components primarily subject to tension, compression, or shear, such as floor pans, roofs, shock towers, etc., should be made from lower cost steel. Recommendations for future research that are consistent with this strategy are included.
Recommended Content
| Technical Paper | Performance Evaluation of PU Over-molded Thermoplastic Steering Wheel |
| Aerospace Material Specification | Interleaf Carrier Material, Composite Tape Differentially Coated Paper, Unperforated 0.0035 inch (0.081 mm) |
| Technical Paper | Structural SMC-Material, Process and Performance Review |
Authors
Topic
Citation
Baskin, D., Dinda, S., and Moore, T., "A Simple Approach to Selecting Automotive Body-in-White Primary-Structural Materials," SAE Technical Paper 2002-01-2050, 2002, https://doi.org/10.4271/2002-01-2050.Also In
References
- Olson G.B. “Materials Design: An Undergraduate Course,” Proceedings for the Morris E. Fine Symposium Liaw P.K. Weertman J.R. Marcus H. L. Sentner J. S. The Minerals, Metals and Materials Society 1991
- Ashby M.F. “Materials and Shape,” Acta Metall. Mater. 39 6 1025 1039 1991
- Asby M.F. “Materials Selection in Conceptual Design,” Proceedings from the Ashby Symposium on Materials Design, ASM World Materials Congress Chicago, IL 1988
- Beer F.B. Johnson E.R. “Mechanics of Materials,” 2nd McGraw-Hill NY, NY 1992
- Luo A.A. “Materials Comparison and Potential Applications of Magnesium Automobiles,” Magnesium Technology 2000 Kaplan H.I. Hryn J. Clow B. TMS 89 97 2000
- Bennet J.A. Nelson M.F. “An Optimization Capability for Automotive Structures,” SAE Paper# 790972 1 9 1979
- Bonnet R.E. Carpenter R.A. Loosle D.G. Provancher R.W. “Structural Composites in a Lightweight Body Structure,” Proceedings from the International Body Engineering Conference 38 44 1995
- Cedar D. A. “Fabrication and Assembly of a Graphite Fiber Reinforced Plastic Vehicle,” SAE Paper# 790029 1 14 1979
- Miel R. “BMW Puts New Design Idea on Carbon-Fiber Diet,” Automotive News 10 23 36D 36F 2000
- Dieffenbach J.R. “Challenging Today's Stamped Steel Unibody: Assessing Prospectus for Steel, Aluminum and Polymer Composites,” Proceedings from the International Body Engineering Conference Stuttgart, Germany 1 6 1997
- Dieffenbach J.R. Mascarin A.E. “Body-in-White Material Systems: A Life-Cycle Cost Comparison,” J. of Metals 6 16 19 1993
- Gibson T.L. “Life Cycle Assessment of Advanced Materials for Automotive Applications,” SAE Paper# 2000-01-1486 1 10 2000
- Mascarin A. E. Wzorek J.F. Rossi G. Brachos V. “Development of a Manufacturing Strategy for Moderate Volume Production of a Composite Vehicle Structure,” SAE Paper # 982400 Proceedings from the International Body Engineering Conference Detroit, MI 1 6 1998
- Mascarin A. E. Wzorek J.F. Rossi G. Brachos V. “Development of a Manufacturing Strategy for Moderate Volume Production of a Composite Vehicle Structure,” SAE Paper # 982400 Proceedings from the International Body Engineering Conference Detroit, MI 1 6 1998
- Rothacker A.H. Pelts G.A. “High Productivity/Low Cost Manufacturing Approach to SRIM Molding,” SAE Paper # 980998 1 3 1998
- Durrani S. “Optimizing Convertible Automotive Design Through the Use of Magnesium,” SAE Paper# 930411 1 6 1993
- Dieter G.E. “Mechanical Metallurgy,” 3rd McGraw-Hill Book Company New York, NY 1986
- Brandt J. Drechsler K. Nohr M. “Crush Behavior of 3D Textile Structural Composites,” Conference Proceedings from the International Body Engineering Conference 105 111 1997
- Doi D.A. Jeryan R.A. Mahmood H.F. Akhtar J.S. Stephens M.P. “Composite Impact Analysis of Race Cars – Technology Transfer to Passenger Car Development,” SAE Paper# 983092 Proceedings from the Motorsports Engineering Conference and Exposition Dearborn, MI 1 5 1998
- Lakshminarayan V. Balagopalan G.K. Yu M. Chen S. “Applications of CAE Nonlinear Finite Element Analysis in the Crashworthiness Development of a Vehicle with Aluminum and Composite Structures,” Proceedings from the International Body Engineering Conference 123 130 1995
- Lee H-K. Simunovic S. “Constitutive Modeling and Impact Simulation of Random Carbon Fiber Polymer Matrix Composite for Automotive Applications,” SAE Paper # 2000-01-1574 1 6 2000
- Maruthayppan R. Balakrishnan P Gupta V. Chan A.W. “A Comparison of Thermoplastic Composites vs. Conventional- Steel Instrument Panel Systems for Side-Impact Energy Management,” SAE Paper # 980962 1 8 1998
- Phillips M. Patberg L. Dittmann R. Adam H. “Structural Analysis and Testing of Composites in Automotive Crashworthiness Application,” SAE Paper # 981140 97 100 1998
- Schmueser D.W. Wickliffe L.E. Mase G.T. “Front Impact Evaluation of Primary Structural Components of a Composite Space Frame,” SAE Paper # 880890 57 65 1988
- Meyer T.N. Kinosz M.J. Bradac E.M. Mbaye M. Burg J.T. Klingensmith M.A. “Ultra Large Casting to Produce Low Cost Aluminum Vehicle Structures,” SAE Paper # 1999-01-2252 1 6 1999
- Dixon-Chandley G. Redemske J.A. Johnson J.N. Shah R.C. Mikkola P.H. “Counter-Gravity Casting Process for Making Thinwall Steel Exhaust Manifolds,” SAE Paper# 970920 145 152 1997
- Beck R.H. Jr. Yurek D.A. “Automotive Structural Bonding,” SAE Paper# 750077 1 14 1975
- Cornille H.J. “The Contribution of Structural Adhesive to Body Structure NVH,” Proceedings from the International Body Engineering Conference 29 39 1994
- Fu M. Mallick P.K. “Performance of Adhesive Joints in an Automotive Composite Structure,” SAE Paper# 2000-01-1131 1 9 2000
- Hart-Smith L.J. “Adhesive Bonding of Aircraft Primary Structures,” SAE Paper# 801209 1 15 1980
- Minichelli J. L. “Bonding Automotive Galvanized Sheet Steel with One-Part Zinc Activated Acrylic Structural Adhesives,” SAE Paper # 910507 1 6 19