Vehicle Side Structure Concept using Ultra High Strength Steel and Rollforming Technology

It is said that rollforming technology is one of the most effective uses of Ultra High Strength Steel (UHSS). The method by which a new vehicle side structure concept can satisfy IIHS (Insurance Institute for Highway Safety) side impact test criteria was studied by utilizing IIHS’s technologies. First of all, the best structural ideas for each part (e.g. B-pillar, side sill, roof cross member and floor cross member, etc.) based on the closed sections utilizing the rollforming technology and UHSS were studied using the crash CAE of each part. The best solutions for each part were assembled on the vehicle side structure CAE model, and the crash performance of the IIHS side impact test was confirmed using the module part of the crash CAE model. The great weight saving possibility of the new vehicle side structure concept was proven by comparing it to the conventional structure concept based on the stamped parts. Prototypes of each part were produced and their performances were confirmed by collapse tests.