Application of Response Surface Methodology to Model Material Thinning in a Chassis Cross Member

In this study an effort has been made to establish a response surface model to predict material thinning in a stamped chassis cross member. Numerical simulations using finite element method were performed to populate the data needed for response surface analysis. The results predicted by the response surface model were compared with the results of numerical simulations and were found to be in good agreement. The effect of corner radius, flange radius and flange height on material thinning was investigated using the response surface model.