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Designing a vehicle body involves meeting numerous performance requirements related to different attributes such as NVH, Durability, Safety, and others. Multi-Disciplinary Optimization (MDO) is an efficient way to develop a design that optimizes vehicle performance while minimizing the weight. Since a body design evolves in course of the product development cycle, it is essential to repeat the MDO process several times as a design matures and more accurate data become available. This paper presents a real life application of the MDO process to reduce weight while optimizing performance over the design cycle of the 2015 Mustang. The paper discusses the timing and results of the applied Multi-Disciplinary Optimization process. The attributes considered during optimization include Safety, Durability and Body NVH. Several iterations of MDO have been performed at different milestones in the design cycle leading to a significant weight reduction of the already optimized design by over 16kg.

A CAE modeling methodology has been developed for modeling laser and MIG (metal-inert-gas) weld separations. This new methodology can simulate weld failure in CAE aluminum vehicle crash analysis using a failure formulation derived from coupon test results. It is a generalized method and is intended to be applicable to any combination of the parameters such as thickness, material, and type of weld and impact speed. The method has been validated on the crash tests on straight and S-type rails with a hat section. The CAE prediction based on the modeling procedure correlates well with the test results for all the rail crush cases. The finite element analysis was conducted in RADIOSS environment. The welds are modeled using the beam-type spring element with the new weld damage parameters. The baseline curves for the spring element and the detailed projection equations developed are provided in this paper.

Ford designed and built a midsize family sedan for the PNGV (Partnership for a New Generation of Vehicle). The side impact performance of the aluminum vehicle and the current CAE capability was studied. The vehicle was tested according to the specifications of FMVSS 214. The results show the vehicle meet the federal safety requirements. The impact performances of the front and rear dummies were comparable to those of the steel counterpart. CAE analysis was conducted to develop the body component design and to predict the structural and dummy responses. The results show that without modeling of the joint (rivet and weld) separation, the accuracy of the CAE crash analysis for this aluminum vehicle was inadequate. When empirical separation criteria were incorporated to model the joint, analysis results correlated with the test. Further development of robust modeling methods for joint separation is needed to improve the prediction of aluminum structure crash responses.