One of the most important targets in automotive research and development is a design layout of the body in white with reduced weight but sufficient crash safety and stiffness. This conflict of aims is only solvable with lightweight constructions including well directed material choice and design features. The deformation behaviour of the side members and bumper beam is of prime importance for passive safety in frontal high and low speed collisions. The target of this investigation is to figure out the weight reduction potential with stainless steel in automotive body structures. Therefore the use of stainless steel for the side members and the bumper beam in a caravan vehicle is analysed with the aid of crash simulation. For the investigation a finite element model of the Dodge Caravan / Chrysler Voyager is used. In the analysis firstly a simple material substitution with a reduction of gages, but without shape modifications is done. Then a redesigned hydroformed member is analysed, that exploits the good formability qualities of stainless steel. The possible weight reduction with stainless steel is 9 % to 28 %, the possible weight reduction with stainless steel and with the new side member design is 19 % to 34 %. In the second part of the study the bumper beam is analysed. A pedestrian friendly design made of stainless steel with a reduced cross section area is developed. The bending stiffness of the stainless steel beams is as high as in the original beam. Even considering pedestrian protection a weight reduction of 38.8 % is possible. This is achieved by a redesign and a stainless steel material substitution.
Application of stainless steel in vehicle crash structures
Einsatz von rostfreiem Stahl in Crashstrukturen von Kraftfahrzeugen
2002
16 Seiten, Bilder, 9 Quellen
Conference paper
English
Application of stainless steel in vehicle crash structures
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