This paper describes the methodology used at DaimlerChrysler Brazil Ltda. (DCBR) for bus chassis frame structure optimization resulting from constant product improvements. The objectives were the reduction of weight and costs for the frame components.
At first, a research about frame structure components current situation was done considering the features, investments, and previous finite element analysis.
Then the modifications were evaluated through static and dynamic numeric simulation analysis. In the end of third analysis step, the results were approved releasing the geometry for a physical prototype construction, that was monitored during the durability test to confirm the weight and cost reduction of about 15% of frame current structure.
After the durability test accomplishment all approved modifications were released for production.