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BIW Design and CAE
Technical Paper
2015-01-0408
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
The Multi Material Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of US Department of Energy project DE-EE0005574. The project demonstrates the light weighting 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 Mach-I 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.
This paper includes details associated with the mass reduction and structural performance of the multi material body in white (BIW) relative to a C/D segment production vehicle. Selected stiffness, durability and crash requirements are assessed. The structure incorporates aluminum castings, extrusions and sheet as well as steel sheet, assembled using structural adhesive bonding and a variety of joining technologies. No other body structure in high volume production incorporates this combination of materials and joining processes.
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Authors
Citation
Conklin, J., Beals, R., and Brown, Z., "BIW Design and CAE," SAE Technical Paper 2015-01-0408, 2015, https://doi.org/10.4271/2015-01-0408.Also In
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