Body Structure Joint Optimization: A Cost Driven Approach

Cross-section properties and joint stiffness properties of the body structure define its characteristic behavior. During the transitional product development process, body structure joints are optimized on an individual basis to reduce cost and weight. The objective of this paper is to present a methodology to analyze the entire body structure design by optimizing each body joint for stiffness and cost. This methodology utilizes joint sensitivity data from FEA, section properties, and cost/weight data. When the joint stiffness status does not meet the target during the design process, the methodology is an effective tool in making decisions regarding the gage increase/decrease for each part constituting body structure joints. Additionally, the methodology has been applied to body structure joints and door upper frame separately.