Car Body Design Research Articles

Strength Analysis of the Railway Truck Body Based on ANSYS

Tub-type car is a kind of truck which increases the usage of the rolling stock clearance. Its special tub-shaped structure provides more space for cargo that increases the load utilization factor. The analysis of the structural strain strength proves that the design and material of the tub-type car body fit the actual demand according to the rules of the <AAR Specification>. The stress of every point everywhere on the structure of the car body is below the yield stress which ensures the safety of the car body during the operation. The simulation results reflect the stress distribution of the whole car body which provides the reference for design and test.

Multi-functional design of a composite high-speed train body structure

A multi-level, multi-functional, optimisation methodology is suggested for the design of a composite high speed train car body. The structure consists of a layer of inner lining (glass fibre/vinyl ...

Design of lightweight magnesium car body structure under crash and vibration constraints

Car body design in view of structural performance and lightweighting is a challenging task due to all the performance targets that must be satisfied such as vehicle safety and ride quality. In this paper, material replacement along with multidisciplinary design optimization strategy is proposed to develop a lightweight car body structure that satisfies the crash and vibration criteria while minimizing weight. Through finite element simulations, full frontal, offset frontal, and side crashes of a full car model are evaluated for peak acceleration, intrusion distance, and the internal energy absorbed by the structural parts. In addition, the first three fundamental natural frequencies are combined with the crash metrics to form the design constraints. The wall thicknesses of twenty-two parts are considered as the design variables. Latin Hypercube Sampling is used to sample the design space, while Radial Basis Function methodology is used to develop surrogate models for the selected crash responses at multiple sites as well as the first three fundamental natural frequencies. A nonlinear surrogate-based optimization problem is formulated for mass minimization under crash and vibration constraints. Using Sequential Quadratic Programming, the design optimization problem is solved with the results verified by finite element simulations. The performance of the optimum design with magnesium parts shows significant weight reduction and better performance compared to the baseline design.

Theoretical Study of Solar Car Based on Finite Element

This paper is concerned with an optimization design for the solar car body under a single load is carried out by using finite element optimization design (FEOD) model. Topology optimization and sizing optimization are explored to find out an optimal manufacturing feasible design from multiple optimized designs of material reinforcement of the solar car body for rigidity improvement. The application of these methods demonstrates that through innovative utilization of the topology optimization technique, an optimal manufacturing feasible design can be obtained. The relationship between the rigidity improvement and different configuration of material reinforcement is also investigated. It is concluded that through appropriate application of FEOD methods, the overall rigidity of the solar car body framework can be improved substantially in a cost effective manner and provides more convincing evidence for optimization design of the solar car body. The results demonstrate that the optimized solar car body is safer and lighter.

Cold-worked austenitic stainless steels in passenger railcars and in other applications

The structural applications of cold-worked austenitic stainless steels are reviewed in a historical perspective, with an emphasis on passenger railcars. The base materials are described, including their mechanical and technological properties. Some notions of car body design are presented, together with the challenges related to design practices involving the discussed materials. The fabrication processes are described. Information on resistance and arc welding processes is provided, including their specific aspects concerning the discussed materials, a description of the equipment, procedures qualification, reference standards, and production control. Challenges relative to the wider application of cold-worked austenitic stainless steels are discussed.

Research on the Key Technologies for EMU Carbody Design CAD System Based on Pro/Toolkit

CAD secondary development is to solve the problem of "personality". In this paper, A CAD System for EMU car-body design was developed based on Pro/Toolkit in Visual C++ Integrated Development Environment. The composition and functions of the system was introduced in details, then several key technologies to realize the function of the system were discussed, including Parametric EMU car-body model building technology based on TBS Database access technology based on Universal Classes Model preview technology based on OCX and Parameter-driven technology.

Influence of anisotropy parameter on deep drawing of tailor welded blanks of low-carbon steels

The influence of difference in thickness, material properties and the weld zone on deep drawing and stretch forming behavior of tailor welded blanks is a critical laboratory scale study before implementation in car body design. Mostly, various low-carbon steel sheets are used for fabrication of tailor welded blanks due to their excellent weldability and formability, and these steel sheets have high normal and planar anisotropy from preprocessing stage due to large deformation cold rolling. In this study, two different tailor welded blanks and one laser welded blank of similar material combination were fabricated by laser welding of interstitial-free, interstitial-free high-strength and high-strength low-alloy steels. Transverse tensile testing of the laser welded blanks of similar material combination (interstitial free–interstitial free) and two tailor welded blank specimens (interstitial free–interstitial free high strength and interstitial free–high strength low alloy) were conducted to evaluate the weld quality in terms of strength and failure location. The effect of anisotropy on formability of tailor welded blanks was investigated in terms of cup depth and fracture location in cylindrical deep drawing process. Finite element simulations of the deep drawing process were conducted using the commercial available nonlinear solver, RADIOSS. It was observed that the Lankford anisotropy parameter, R-value, influences the thickness distribution, weldline movement and failure location in tailor welded blanks.

Taguchi Robust Design of Exhaust System Based on the Parametrically Process of Parts Location

Due to the change of car-body design, the location of exhaust systems hanger is uncertain and always fluctuates around the initial design position. So the Taguchi method is introduced to conduct exhaust systems optimal design. Firstly, the parameterization of hanger location under the grid environment was realized by combining NastranHypermesh and Isight. Then, the Taguchi robust design of the exhaust system is performed taking the hanger location as noise factors and the stiffness of hanger shock absorber as control factors. As a result, modal property and robustness of the exhaust system are improved. At last, the results of Taguchi robust design and traditional sensitivity optimization design based on the finite element method are compared, which reveals the advantage of Taguchi robust design in improving product quality.

Application of the High Strength Steel in the Automobile

With the development of automotive industry, new high strength and high performance steel sheets are used more and more widely, which are the basis of weight reduction and safety improvement for automobiles. Taking examples of the design of car body, this paper focused on the remarkable effects of the application of AHSS in automobile lightweight, car safety and environment. It was also pointed out that the key topics will fall in the forming technique of AHSS and the applications of AHSS to new car body design to enhance automobile safety.

2212 製品設計へのRFLPアプローチ適用に関する考察

In recent years, with the advancement of technologies and globalization, the complexity and diversifications of the products are being increased in parallel. At the same time, to improve its efficiency, the process and the IT infrastructure for the product development need to be sophisticated and globalized. The products are also required to be multidisciplinary and reasonably optimized while there are a lot of trade-off and negotiations among the departments and domain experts. In this situation, there are newly emerging problems and challenges like ensuring the consistency and traceability on the complex system of the products and the idea of systems engineering receives much more attention. In this paper, we introduce the RFLP approach to achieve systems engineering based on V-model and model-based development and propose the guidance of its application for early-stage product development. We also made some studies on its effectiveness with some examples of printer and car body design for each specific target.

Employ the Taguchi Method to Optimize BPNN’s Architectures in Car Body Design System

Previous research works tried to optimize the architectures of Back Propagation Neural Netwo rks (BPNN) in order to enhance their performance. However, the using of appropriate method to perform this task still needs expanding knowledge. The paper studies the effect and the benefit of using Taguchi method to optimize the architecture o f BPNN car body design system. The paper started with literatures review to define factors and level of BPNN parameters for number of hidden layer, nu mber of neurons, learn ing algorithm, and etc. Then the BPNN arch itecture is optimized by Taguchi method with Mean Square Error (MSE) indicator. The Signal to No ise (S/N) ratio, analysis of variance (ANOVA) and analysis of means (ANOM) have been employed to identify the Taguchi results. The optimal BPNN training has been used successfully to tackle uncertain of h idden layer's parameters structure. It has faster iterations to reach the convergent condition and it has ten times better MSE achievement than NN machine expert. The paper still shows how to use the informat ion of car body shapes, car speed, vibration, noise, and fuel consumption of the car body database in BPNN training and validation.

The Application of Hybrid Design Method in Car Body Design

Reverse design and forward design have their strong points each other. The advantages of reverse design lie in the treatment of free-form complex modeling, while forward design is good in modeling in simpler feature. The car body often contains complex curved surface and some simple features. Through a single reverse or forward design can’t realize the efficient design. In order to combine advantages of reverse and forward design, using the hybrid design process design can improve the efficiency of the development of car body.

Car Body and Chassis Development of UKM CARevo for Perodua Eco-Challenge 2011

This paper presents the development of the UKM Perodua Eco-Challenge vehicle, CARevo in terms of aesthetic design, novel fabrication of car body and superior chassis design. The objective of the competition was to develop a fuel efficient car which was competent to travel the longest distance using 0.5 liter of RON95 fuel with some rules and regulation verified by the Perodua to be followed. The UKM CARevo was powered by a 660cc fuel injection engine with manual 5-speed transmission with the total of 3450 mm, 1500 mm and 1106 mm for its length, wide and height. Several design such as space frame chassis design, composite bodywork result from fiberglass with resin, aerodynamic design of car body and are the key features that is discussed in this paper.

Application of the High Strength Steel in the Automobile

With the development of automotive industry, new high strength and high performance steel sheets are used more and more widely, which are the basis of weight reduction and safety improvement for automobiles. Taking examples of the design of car body, this paper focused on the remarkable effects of the application of AHSS in automobile lightweight, car safety and environment. It was also pointed out that the key topics will fall in the forming technique of AHSS and the applications of AHSS to new car body design to enhance automobile safety.

Modal Analysis and Local Stiffness Optimization for Body-in-white of Car

AbstractUsing preprocessing software Hypermesh and FEA software MSC. Nastran, the detailed finite element model of car body-in-white (BIW) was established based on the theory of finite element. Finite element modal analysis and experimental modal analysis were conducted to get the modal parameters of BIW including natural frequencies and corresponding mode shapes respectively. With comparison of the result of the simulation with that of test, the validity of the FEA model was verified. From the view of vibration and strength, the impact of internal and external incentives on the BIW was analyzed. According to strain mode local characteristics, a new method to determine the position where the maximum elastic deformation takes place by using the strain energy distribution of the vibration modes of different orders was therefore proposed. The method can be used to improve the local rigidity of BIW. The result shows that this method is reasonable and practical for the car body design.

전복시 차체에 대한 구조 안전 해석

본 연구에서는 구조해석을 통하여 차체의 전복 시에 있어서의 차체의 두께에 따른 변형량과 응력 변화를 고찰하여 보았다. 차체의 두께가 5t인 자동차에서는 2초일 때에 차체의 오른쪽 천장에서 7.5024mm의 최대변형이 일어났으며, 차체의 왼쪽 밑 부분에서 113.69 MPa의 최대응력을 받았다. 차체의 두께가 10t인 자동차에서는 2초일 때에 차체의 오른쪽 천장에서 1.2557mm로 최대의 변형이 일어났으며 차체의 왼쪽 밑 부분에서 15.134 MPa의 최대응력이 발생했다. 차체의 두께가 15t인 자동차에서는 2초일 때에 0.42529mm로서 차체의 오른쪽 천장에서 최대의 변형이 일어났으며 응력은 2초일 때에 차체의 왼쪽 밑 부분에서 4.405MPa의 최대응력이 작용되었다. 두께가 15mm보다 커지는 경우에는 시간에 따른 응력 및 변형율의 분포가 고르게 나타나고 있어 설계의 안전성을 보이고 있다. In this study, the changes of displacement and stress are investigated by structural analysis according to the thickness of car body in case of overturn. In case of 5 mm thickness, the maximum displacement of 7.5024 mm at its right ceiling and the maximum equivalent stress of 113.69 MPa at the left lower part are occurred on the elapsed time of 2 second. In case of 10 mm thickness, the maximum displacement of 1.2557 mm at its right ceiling and the maximum equivalent stress of 15.134 MPa at the left lower part are occurred on the elapsed time of 2 second. In case of 15 mm thickness, the maximum displacement of 0.426067 mm at its right ceiling and the maximum equivalent stress of 4.4842 MPa at the left lower part are occurred on the elapsed time of 2 second. As stress and displacement are uniformly distributed according to time in this case, the design of car body can be stabilized.

Numerical Analysis of Hybrid Joining in Car Body Applications

Nowadays, there are two fundamental issues in car body design. On the one hand, there is the need for weight reduction in order to reduce fuel consumption and, consequently, pollutant emissions, and on the other hand, there are ever more stringent safety requirements. To meet these targets, the trend is towards using hybrid structures made of unconventional materials, like aluminium, polymeric and composite materials. The use of these materials brings about some problems, one of them is associated with the joining techniques because the traditional resistance spot-welding, used in the assembly of a common steel chassis, cannot be used. Among the different alternative solutions, the most promising is the use of structural adhesives. From this perspective, this work aims to model the behaviour of simplified crash box elements made of different types of materials joined together by structural adhesives. In particular, the attention was focused on the adhesive joint modelling with a cohesive element formulation. Starting from experimental results for the characterization of the adhesive, the cohesive parameters were identified. The results were then applied to model the crushing of simplified crash boxes. The crushing axial compression of these components was investigated considering geometrical and loading conditions. The models were developed and verified by comparing the numerical with experimental results on these components. A good correlation was found in all loading conditions and with different geometries and substrate combinations.

Three-phase optimisation design of an electric car body at conceptual design stage

A three–phase optimisation design method is proposed in the paper. It is composed of two steps of topology optimisation and one step of size optimisation, and used for design of a mini electric car Body In White (BIW) at conceptual design stage. The method provides an opportunity to comprehend performances of the body construction under different load conditions in detail. Final result of the optimised BIW achieves 31% weight reduction with improved stiffness, strength and the first–order frequency compared with previous design.

Comparison of matching layers for automotive radome design

Abstract. Hidden integration of 79 GHz sensors behind plastic and painted fascia represents a challenging task since both electromagnetic and car body design constraints have to be met. This paper compares different possibilities for low-cost integration of radar sensors. Based on a model for stratified media, a study of the most important parameters such as bandwidth, angle and tolerances is shown. Our results suggest that for plastic fascia, the requirements of future radar sensors can be met with low-cost matching. Even with metallic paints, the requirements imposed by modern 79 GHz radar sensors can be met under certain conditions.

Bi-Material Joining for Car Body Structures: Experimental and Numerical Analysis

Crashworthiness is an important issue in car body design: it describes the ability of the vehicle structure to behave efficiently by absorbing and dissipating energy in a stable and controlled manner during a crash event. Energy management during frontal impact is mainly done through crash boxes in the front rails. These crash boxes are usually slender, thin-walled steel columns, progressively collapsing during impact. Due to a trend in lightweight materials use, it is necessary to gain knowledge about the material behaviour and alternative joining systems. The use of an adhesive as a joining system for different materials was investigated by means of experimental tests on specimens and simple components, made of aluminium and deep drawing steel. A numerical simulation technique was developed to describe and understand the phenomenon. Furthermore, since the behaviour is influenced by the loading rate and the materials used in this application are known to be strain-rate sensitive, static and impact loading conditions were examined.