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A New Numerical Method for Potential Analysis and Design of Hybrid Components from Full Vehicle Simulations: Implementation and Component Design

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Technologies for economic and functional lightweight design

Abstract

To exploit the lightweight potential of common materials like steel, aluminum or especially fiber-reinforcement plastics (FRP), a load-compliant material concept is mandatory. In keeping with the motto “the best material for the best application”, a new approach for a tailored material distribution between FRP and metals is proposed. By defining a scalar value referred as “uniaxiality” and a uniaxiality weighted sensitivity, a numerical method is implemented to identify body-in-white (BIW) components with a high amount of anisotropic loading. The uniaxiality value is gathered from full vehicle crash simulations and is superpositioned over all load cases to access a generalized information which component’s area is suitable for isotropic materials like metals and which one for anisotropic materials like FRP. In the next step, a functional component group consisting of an A-pillar and a roof frame section is exemplary engineered by using the findings of the numerical potential analysis. The developed extreme lightweight concept made of aluminum extrusion, unidirectional carbon fiber-reinforcement plastics (CFRP) tapes, warm stamped aluminum and press-hardened steel demonstrates outstanding performance that has been proven in full vehicle crash simulations and experimental tests. Furthermore, the concept is evaluated in terms of the components CO2 footprint and costs. Based on these data a scalable component concept is possible to meet customer specific requirements between the design objectives: lightweight, costs and environmental impact.

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Acknowledgements

The authors gratefully acknowledge the funding of the project by BENTELER Automobiltechnik GmbH. Sincere thanks also due to the Paderborn Center for Parallel Computing (pc2) for the provided computing time. Special thanks are due to Caterina Linnig, Jan Striewe, Bamned Sanitther, Gero Müllers and last but not least Dr. Jörn Tölle for their support and valuable discussions.

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Correspondence to Thomas Tröster .

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Tröster, T., Camberg, A.A., Wingenbach, N., Hielscher, C., Grenz, J. (2021). A New Numerical Method for Potential Analysis and Design of Hybrid Components from Full Vehicle Simulations: Implementation and Component Design. In: Dröder, K., Vietor, T. (eds) Technologies for economic and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-62924-6_30

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  • DOI: https://doi.org/10.1007/978-3-662-62924-6_30

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  • Publisher Name: Springer Vieweg, Berlin, Heidelberg

  • Print ISBN: 978-3-662-62923-9

  • Online ISBN: 978-3-662-62924-6

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