This content is not included in your SAE MOBILUS subscription, or you are not logged in.

InCar - Advanced Door Design

Journal Article
2012-01-0782
ISSN: 1946-3979, e-ISSN: 1946-3987
Published April 16, 2012 by SAE International in United States
InCar - Advanced Door Design
Sector:
Citation: Bhagwan, A., McKune, P., Faath, T., and Knoerr, L., "InCar - Advanced Door Design," SAE Int. J. Mater. Manf. 5(1):235-246, 2012, https://doi.org/10.4271/2012-01-0782.
Language: English

Abstract:

The ThyssenKrupp InCar Project is a comprehensive R&D development that gives automotive manufacturers modular solution kits for body, chassis and powertrain applications. The solution kits developed within this project offer weight reduction, cost savings or improved functionality. This paper will focus on the two front door solutions developed within the InCar project. The first door solution, called the Lightweight Door, achieved a 13% weight reduction. This door features a 4-piece tailored blank inner panel and a sandwich material outer panel. The second door solution, called the Advanced Door, is a completely new and innovative door architecture that uses a 2-piece tailored blank mid panel and ultra thin Dual Phase 500 outer panel to achieve an 11% weight reduction. Prototypes were manufactured and tested for both door solutions. This paper will provide a detailed description of everything related to the development of these door solutions, including manufacturing and assembly processes, performance, materials, and cost estimation.