Lightweight design with stainless steel

DYNAmore LS-DYNA Forum 2002, Bad Mergentheim, September 2002

Dipl.-Ing. F. Friesen,
Dipl.-Ing. D. Schwarz, Institut für Kraftfahrwesen Aachen (ika)
Dipl.Ing. P.-J. Cunat, Euro Inox, Brussels

Summary:

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. Examples therefore are the use of steels with high strength or modern manufacturing methods like hydroforming or tailored blanking.
The deformation behaviour of the side members and bumper beam is of prime importance for passive safety in frontal high and low speed collisions. Pedestrian protection is another aspect that has to be taken into account in modern vehicles. For this reason the use of stainless steel in conjunction with design modifications for side members and bumper beam is investigated.
For this investigation a LS-DYNA finite element model of the Dodge Caravan / Chrysler Voyager is used. This model has been built up by the FHWA/NHTSA National Crash Analysis Center [National Crash Analysis Center, 1999] and validated with real crash tests.




Weight reduction potential for high speed crash - material substitution